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Service Manual Part No. 36540 Rev C August 2008 (before serial number 6291) (before serial number 5427) Introduction First Edition • Third Printing Z-34/22 Z-34/22N TM TM Important Read, understand and obey the safety rules and operating instructions in the Genie Z-34/22 & Genie Z-34/22N Operator’s Manual before attempting any maintenance or repair procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting and repair procedures for qualified service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center. Genie Industries has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and other manuals. Please write to the technical publications team in care of Genie Industries, PO Box 97030, Redmond WA 98073-9730 USA. ® Copyright © 1996 by Genie Industries First Edition: First Printing June, 1996 Second Printing February, 2000 First Edition: Third Printing August, 2008 "Genie" and "Z" are registered trademarks of Genie Industries in the U.S.A. and many other countries. Printed on recycled paper Printed in U.S.A. If you have any questions, please contact Genie Industries. Contact us: http://www.genielift.com e-mail: [email protected] ii Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie Z-34/22 & Genie Z-34/22N Operator’s Manual will result in death or serious injury. Many of the hazards identified in the operator’s manual are also safety hazards when maintenance and repair procedures are performed. Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturer’s instructions and safety rules - employer’s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N iii First Edition • Third Printing SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following: Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. Indicates special operation or maintenance information. iv Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Theory of Operation Power Source Electrical System The Genie Z-34/22 & Genie Z-34/22N are powered by eight six-volt (315 AH) batteries, separated into two groups of four. Each group of four batteries is wired in series to produce 24V DC. The two battery groups are then joined to produce 48V DC. The drive system uses 48V DC and the control system uses 24V DC. Drive system Hydraulic System All machine functions are performed by the hydraulic system. The hydraulic system is powered by a single-section gear pump. When the pump is activated, it supplies hydraulic fluid under pressure to the function manifold, where the control valves are located. To protect from over-pressurization of the hydraulic system, the pump is provided with a pressure relief valve, set at 3200 psi (221 bar). Activating a machine function is accomplished by actuating or moving a toggle switch and/or control handle, which sends voltage to the appropriate directional control valve. The directional valve determines which direction the hydraulic fluid will travel. The amount of hydraulic fluid volume is determined by the proportional valve input voltage from the boom function speed controller at the platform controls. Each boom lift cylinder incorporates a counterbalance valve to prevent movement in the event of a hydraulic line failure. Part No. 36540 All Z-34/22 and Z-34/22N machines utilize a DC drive motor on each non-steer wheel. The two motors are connected in series and are controlled by a solid-state motor controller. The motor controller regulates the amount of current applied to the drive motors based upon the position of the drive controller (joystick), which allows proportional drive speed control. Z-34/22 machines (before serial number 1734) and Z-34/22N machines (before serial number 2227) use series-wound DC drive motors and a solid state motor controller designed for series motors. A mechanical forward/reverse contactor provides directional control of the drive motors. These machines also have a proportional braking system, which is active in the drive controller (joystick) range between neutral position and half way to full deflection in both drive directions. The drive controller has a 0-5 V DC voltage output which activates the motor controller, as well as a proportional coil output for the brake system. Z-34/22 machines (after serial number 1733) and Z-34/22N machines (after serial number 2226) use separately excited (Sepex) DC drive motors and a Sepex motor controller. No forward/reverse contactor is required in this system, as the controller does the switching automatically. The Sepex drive system utilizes regenerative braking, which means that the drive motors are used to slow down and stop the machine. The resulting Genie Z-34/22 & Genie Z-34/22N v First Edition • Third Printing THEORY OF OPERATION energy is then returned to the batteries. Regenerative braking allows the use of a simple, non-proportional parking brake which applies after the machine has come to a stop, or if the Emergency Stop button is pushed in to the OFF position. The Sepex motor controller also incorporates self diagnostics. An LED on the motor controller will flash a fault code when a fault is present to aid in troubleshooting. Refer to the fault code chart in Section Five. Limit switches There are two types of limit switches, which are found in various locations on the machine: drive speed limit switches and a drive enable limit switch. The function of a drive speed limit switch is to limit the raised machine drive speed to 0.6 miles per hour (1 km/h) when either the primary or secondary boom is raised more than 2 feet (0.6 m) OR when the primary boom is extended more than 12 inches (30 cm). The function of the drive enable limit switch is to limit the ability of the machine to drive when the boom is rotated outside the area between the nonsteer wheels. Machine Controls The Z-34/22 and Z-34/22N machines are equipped with operational controls which are found in two locations: the ground controls, located opposite the hydraulic tank side of the machine, and the platform controls, located in the platform. All lift and drive functions are available at the platform controls. Only boom functions are available at the ground controls. Moving a boom function toggle switch in the direction indicated on the control panel decal will determine which boom function will operate and its direction of travel. The platform controls incorporates a rotary boom function speed controller which, by varying the position of the controller, controls the amount of voltage to the boom function proportional valve. This controller determines the speed at which the function will operate. The drive controller (joystick) is fitted with a potentiometer that communicates the drive controller position with the motor controller. A thumb rocker switch on the top of the drive controller is used for steering. Washing electronic components is not suggested. Instead, use compressed air to remove debris. Component damage hazard. Avoid shock or impact to the motor controller. Internal damage may not be visible from the outside. vi Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Table of Contents Introduction Important Information ...................................................................................................... ii Section One Safety Rules General Safety Rules ..................................................................................................... iii Theory of Operation ....................................................................................................... v Section Two Specifications Machine Specifications ............................................................................................. 2 - 1 Performance Specifications ...................................................................................... 2 - 2 Hydraulic Specifications ............................................................................................ 2 - 3 Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 4 SAE and Metric Fastener Torque Chart ..................................................................... 2 - 5 Section Three Scheduled Maintenance Inspections Introduction ............................................................................................................... 3 - 1 Table A ..................................................................................................................... 3 - 2 Table B ..................................................................................................................... 3 - 2 Table C ..................................................................................................................... 3 - 4 Table D ..................................................................................................................... 3 - 4 Maintenance Inspection Report ................................................................................. 3 - 5 Section Four Scheduled Maintenance Procedures Introduction ............................................................................................................... 4 - 1 Part No. 36540 A-1 Inspect the Operator’s and Safety Manuals ..................................................... 4 - 2 A-2 Inspect the Decals and Placards ..................................................................... 4 - 2 A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 3 A-4 Check the Hydraulic Oil Level ......................................................................... 4 - 3 Genie Z-34/22 & Genie Z-34/22N vii First Edition • Third Printing TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures, continued A-5 Check for Hydraulic Leaks ............................................................................... 4 - 4 A-6 Test the Platform and Ground Controls ............................................................ 4 - 5 A-7 Test the Auxiliary Power Operation ................................................................. 4 - 7 A-8 Test the Tilt Sensor ......................................................................................... 4 - 8 A-9 Test the Limit Switches ................................................................................... 4 - 8 A-10 Test the Lift/Drive Select Switch (if equipped) ............................................... 4 - 11 A-11 Perform 30 Day/50 Hour Service ................................................................... 4 - 11 B-1 Check the Batteries ....................................................................................... 4 - 12 B-2 Inspect the Electrical Wiring .......................................................................... 4 - 13 B-3 Inspect the Tires and Wheels (including lug nut torque) ................................. 4 - 14 B-4 Confirm the Proper Brake Configuration ......................................................... 4 - 14 B-5 Check the Oil Level in the Drive Hubs ........................................................... 4 - 15 B-6 Test the Key Switch ...................................................................................... 4 - 16 B-7 Test the Emergency Stop Buttons ................................................................. 4 - 16 B-8 Test the Ground Control Override .................................................................. 4 - 17 B-9 Test the Platform Self-leveling ...................................................................... 4 - 17 B-10 Test the Horn ................................................................................................ 4 - 18 B-11 Test the Foot Switch ..................................................................................... 4 - 18 B-12 Test the Drive Enable System ....................................................................... 4 - 19 B-13 Test the Drive Brakes .................................................................................... 4 - 20 B-14 Test the Drive Speed - Stowed Position ........................................................ 4 - 21 B-15 Test the Drive Speed - Raised or Extended Position ..................................... 4 - 22 B-16 Test the Alarm Package (if equipped) ............................................................ 4 - 23 viii Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures, continued B-17 Test the Turntable Rotation Stop ................................................................... 4 - 24 B-18 Check the Electrical Contactors .................................................................... 4 - 25 B-19 Perform Hydraulic Oil Analysis ...................................................................... 4 - 25 B-20 Replace the Hydraulic Tank Return Filter ....................................................... 4 - 26 Section Five C-1 Check the Primary Boom Wear Pads ............................................................ 4 - 28 C-2 Check the Turntable Rotation Bearing Bolts .................................................. 4 - 28 C-3 Check the Free-wheel Configuration .............................................................. 4 - 30 C-4 Grease the Turntable Rotation Bearing and Worm Drive Gear ........................ 4 - 31 C-5 Replace the Drive Hub Oil ............................................................................. 4 - 31 C-6 Bleed the Platform Rotator ............................................................................ 4 - 32 D-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 33 D-2 Grease the Steer Axle Wheel Bearings - 2WD Models ................................... 4 - 35 Troubleshooting Flow Charts Introduction .............................................................................................................. 5 - 1 Fault Code Chart (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) .................................................................. 5 - 3 Part No. 36540 1 All Functions Will Not Operate ......................................................................... 5 - 7 2 Lift Pump Motor Will Not Operate .................................................................. 5 - 10 3 Auxiliary Pump Motor Will Not Operate .......................................................... 5 - 17 4 All Functions Inoperative, Power Unit Starts and Runs .................................. 5 - 20 5 All Lift and Steer Functions Inoperative, Drive Function Operational .............. 5 - 21 6 Ground Controls Inoperative, Platform Controls Operate Normally ................. 5 - 25 Genie Z-34/22 & Genie Z-34/22N ix First Edition • Third Printing TABLE OF CONTENTS Section Five x Troubleshooting Flow Charts, continued 7 Platform Controls Inoperative, Ground Controls Operate Normally (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) ............................................................. 5 - 27 8 Platform Controls Inoperative, Ground Controls Operate Normally (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ................................................................ 5 - 31 9 Primary Boom Up Function Inoperative ......................................................... 5 - 34 10 Primary Boom Down Function Inoperative ..................................................... 5 - 38 11 Secondary Boom Up Function Inoperative ..................................................... 5 - 42 12 Secondary Boom Down Function Inoperative ................................................ 5 - 46 13 Primary Boom Extend Function Inoperative ................................................... 5 - 50 14 Primary Boom Retract Function Inoperative .................................................. 5 - 55 15 Turntable Rotate Left Function Inoperative .................................................... 5 - 60 16 Turntable Rotate Right Function Inoperative .................................................. 5 - 65 17 All Platform Level Functions Inoperative ....................................................... 5 - 69 18 Platform Level Up Function Inoperative ......................................................... 5 - 71 19 Platform Level Down Function Inoperative ..................................................... 5 - 76 20 Platform Rotate Left Function Inoperative ...................................................... 5 - 80 21 Platform Rotate Right Function Inoperative ................................................... 5 - 84 22 Jib Boom Up Function Inoperative ................................................................. 5 - 88 23 Jib Boom Down Function Inoperative ............................................................. 5 - 91 24 Steer Left Function Inoperative (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) ............................................................. 5 - 94 25 Steer Left Function Inoperative (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ................................................................ 5 - 95 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing TABLE OF CONTENTS Section Five Troubleshooting Flow Charts, continued 26 Steer Right Function Inoperative (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) ............................................................. 5 - 97 27 Steer Right Function Inoperative (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ................................................................ 5 - 98 28 All Drive Functions Inoperative, All Other Functions Operate Normally (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) ............................................................ 5 - 100 28A Brake Function Inoperative (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) ............................................................ 5 - 106 29 All Drive Functions Inoperative, All Other Functions Operate Normally (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ............................................................... 5 - 110 29A Motor Controller Fault Code 21: Throttle Fault (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ............................................................... 5 - 112 29B Motor Controller Fault Code 32: Main Contactor Welded (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ............................................................... 5 - 113 29C Motor Controller Fault Code 34: Missing Main Contactor OR Main Contactor Did Not Close (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ............................................................... 5 - 114 30 Part No. 36540 Brake Release Function Inoperative (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ............................................................... 5 - 117 Genie Z-34/22 & Genie Z-34/22N xi First Edition • Third Printing TABLE OF CONTENTS Section Five xii Troubleshooting Flow Charts, continued 31 Drive Forward Function Inoperative .............................................................. 5 - 120 (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) 32 Drive Reverse Function Inoperative .............................................................. 5 - 121 (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) 33 Machine Will Not Drive At Full Speed (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) ............................................................ 5 - 122 34 Machine Will Not Drive At Full Speed (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ............................................................... 5 - 123 35 Machine Drives At Full Speed With Platform Raised Or Extended (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) ............................................................ 5 - 125 36 Machine Drives At Full Speed With Platform Raised Or Extended (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ............................................................... 5 - 126 37 Drive Enable System Is Malfunctioning (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) ............................................................ 5 - 127 38 Drive Enable System Is Malfunctioning (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ..................................................... 5 - 129 39 Remote Brake Release Inoperative Z-34/22 before serial number 3578 and Z-34/22N before serial number 4261) ............................................................ 5 - 130 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing TABLE OF CONTENTS Section Six Schematics Introduction ............................................................................................................... 6 - 1 Electrical Components .............................................................................................. 6 - 2 Load Sensor Option Diagram (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) ......................................................................... 6 - 4 Load Sensor Option Diagram (Z-34/22 from serial number 1734 to 2060 and Z-34/22N from serial number 2227 to 2870) ............................................................... 6 - 5 Load Sensor Option Diagram (Z-34/22 from serial number 2061 to 3577 and Z-34/22N from serial number 2871 to 4260) ............................................................... 6 - 6 Power Cable Diagram (Z-34/22 before serial number 3578 and Z-34/22N before serial number 4261) ......................................................................... 6 - 7 Power Cable Diagram (Z-34/22 after serial number 3577 and Z-34/22N after serial number 4260) ........................................................................... 6 - 8 Abbreviations Legend ................................................................................................ 6 - 9 Electrical Symbols Legend ...................................................................................... 6 - 10 Hydraulic Symbols Legend ...................................................................................... 6 - 11 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N xiii First Edition • Third Printing TABLE OF CONTENTS Section Six Schematics, continued Electrical Schematic (Z-34/22 before serial number 153 and Z-34/22N before serial number 304) ......................................................................... 6 - 13 Electrical Schematic (Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226) ............................................................... 6 - 15 Electrical Schematic (Z-34/22 from serial number 1734 to 1834 and Z-34/22N from serial number 2227 to 2447) ............................................................. 6 - 17 Electrical Schematic (Z-34/22 from serial number 1835 to 2060 and Z-34/22N from serial number 2448 to 2870) ............................................................. 6 - 19 Electrical Schematic (Z-34/22 from serial number 2061 to 3577 and Z-34/22N from serial number 2871 to 4260) ............................................................. 6 - 21 Electrical Schematic (Z-34/22 from serial number 3578 to 4799 and Z-34/22N from serial number 4261 to 5619) ............................................................. 6 - 23 Electrical Schematic (Z-34/22 after serial number 4799 and Z-34/22N after serial number 5619) ......................................................................... 6 - 25 Electrical Schematic - CE Models (Z-34/22 after serial number 4799 and Z-34/22N after serial number 5619) ......................................................................... 6 - 27 xiv Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing TABLE OF CONTENTS Section Six Schematics, continued Ground Control Panel Legend (Z-34/22 before serial number 153 and Z-34/22N before serial number 304) ......................................................................... 6 - 29 Ground Control Panel Wiring Diagram (Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226) ............................................................... 6 - 30 Ground Control Panel Wiring Diagram (Z-34/22 from serial number 1734 to 1999 and Z-34/22N from serial number 2227 to 2750) ............................................................. 6 - 31 Ground Control Panel Wiring Diagram (Z-34/22 from serial number 2000 to 3577 and Z-34/22N from serial number 2751 to 4260) ............................................................. 6 - 32 Ground Control Panel Wiring Diagram (Z-34/22 from serial number 3578 to 4799 and Z-34/22N from serial number 4261 to 5619) ............................................................. 6 - 33 Ground Control Panel Wiring Diagram (Z-34/22 after serial number 4799 and Z-34/22N after serial number 5619) ......................................................................... 6 - 34 Ground Control Terminal Strip Wiring Diagram (Z-34/22 after serial number 4799 and Z-34/22N after serial number 5619) ......................................................................... 6 - 35 Platform Control Box Wiring Diagram (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) ....................................................................... 6 - 36 Platform Control Box Wiring Diagram (Z-34/22 from serial number 1734 to 1834 and Z-34/22N from serial number 2227 to 2448) ............................................................. 6 - 37 Platform Control Box Wiring Diagram (Z-34/22 from serial number 1835 to 2060 and Z-34/22N from serial number 2449 to 2870) ............................................................. 6 - 38 Platform Control Box Wiring Diagram (Z-34/22 from serial number 2061 to 3577 and Z-34/22N from serial number 2871 to 4260) ............................................................. 6 - 39 Platform Control Box Wiring Diagram (Z-34/22 after serial number 3577 and Z-34/22N after serial number 4260) ......................................................................... 6 - 40 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N xv First Edition • Third Printing TABLE OF CONTENTS Section Six Schematics, continued Hydraulic Schematic (Z-34/22 before serial number 674 and Z-34/22N before serial number 935) ......................................................................... 6 - 41 Hydraulic Schematic (Z-34/22 from serial number 674 to 1733 and Z-34/22N from serial number 935 to 2226) ............................................................... 6 - 42 Hydraulic Schematic (Z-34/22 from serial number 1734 to 2005 and Z-34/22N from serial number 2227 to 2771) ............................................................. 6 - 43 Hydraulic Schematic (Z-34/22 from serial number 2006 to 2900 and Z-34/22N from serial number 2772 to 3532) ............................................................. 6 - 44 Hydraulic Schematic (Z-34/22 after serial number 2900 and Z-34/22N after serial number 3532) ......................................................................... 6 - 45 xvi Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing TABLE OF CONTENTS Section Seven Repair Procedures Introduction ............................................................................................................... 7 - 1 Platform Controls 1-1 Controllers ....................................................................................................... 7 - 2 1-2 Foot Switch ..................................................................................................... 7 - 9 1-3 Toggle Switches ............................................................................................ 7 - 10 Platform Components 2-1 Platform ........................................................................................................ 7 - 11 2-2 Platform Leveling Slave Cylinder ................................................................... 7 - 11 2-3 Platform Rotator ............................................................................................ 7 - 13 Jib Boom Components 3-1 Jib Boom ....................................................................................................... 7 - 16 3-2 Jib Boom Bell Crank ...................................................................................... 7 - 17 3-3 Jib Boom Lift Cylinder ................................................................................... 7 - 18 Primary Boom Components 4-1 Plastic Cable Track ....................................................................................... 7 - 19 4-2 Primary Boom ............................................................................................... 7 - 19 4-3 Primary Boom Lift Cylinder ............................................................................ 7 - 23 4-4 Extension Cylinder ........................................................................................ 7 - 25 4-5 Platform Leveling Master Cylinder ................................................................. 7 - 26 Secondary Boom Components Part No. 36540 5-1 Secondary Boom ........................................................................................... 7 - 29 5-2 Secondary Boom Lift Cylinder ....................................................................... 7 - 33 Genie Z-34/22 & Genie Z-34/22N xvii First Edition • Third Printing TABLE OF CONTENTS Section Seven Repair Procedures, continued Ground Controls 6-1 Control Relays ............................................................................................... 7 - 34 6-2 Toggle Switches, See 1-3, Toggle Switches .................................................. 7 - 36 6-3 Wago® Components ...................................................................................... 7 - 36 Hydraulic Pumps 7-1 Auxiliary Pump .............................................................................................. 7 - 37 7-2 Main Function Pump ..................................................................................... 7 - 38 Manifolds xviii 8-1 Function Manifold Components (Z-34/22 before serial number 674 and Z-34/22N before serial number 935) ............................................................... 7 - 40 8-2 Function Manifold Components (Z-34/22 from serial number 674 to 1733 and Z-34/22N from serial number 935 to 2226) ..................................................... 7 - 42 8-3 Function Manifold Components (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ................................................................ 7 - 44 8-4 Valve Adjustments - Function Manifold ......................................................... 7 - 46 8-5 Jib Boom / Platform Rotate Manifold Components (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) ............................................................. 7 - 51 8-6 Jib Boom / Platform Rotate Manifold Components (Z-34/22 from serial number 1734 to 2005 Z-34/22N from serial number 2227 to 2771) ................................................... 7 - 52 8-7 Jib Boom / Platform Rotate Manifold Components (Z-34/22 after serial number 2005 and Z-34/22N after serial number 2771) ................................................................ 7 - 53 8-8 Steer / Brake Manifold Components (Z-34/22 before serial number 781 and Z-34/22N before serial number 1030) ............................................................. 7 - 54 8-9 Steer / Brake Manifold Components (Z-34/22 from serial number 781 to 1733 Z-34/22N from serial number 1030 to 2226) ................................................... 7 - 55 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing TABLE OF CONTENTS Section Seven Repair Procedures, continued Hydraulic Tank 9-1 Hydraulic Tank .............................................................................................. 7 - 56 Turntable Rotation Components 10-1 Turntable Rotation Hydraulic Motor ................................................................ 7 - 58 Steering Axle Components 11-1 Yoke and Hub ................................................................................................ 7 - 59 11-2 Steering Cylinder ........................................................................................... 7 - 61 11-3 Tie Rod .......................................................................................................... 7 - 61 Non-steering Axle Components 12-1 Drive Motor .................................................................................................... 7 - 62 12-2 Drive Hub ...................................................................................................... 7 - 62 Motor Controller 13-1 Motor Controller (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) ................................................................ 7 - 64 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N xix First Edition • Third Printing This page intentionally left blank. xx Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 2 • Specifications Specifications Machine Specifications Tires and wheels, Z-34/22 Stowed dimensions Z-34/22N Z-34/22 Length 18 ft 7 in 5.7 m 18 ft 6 in 5.6 m Width 4 ft 10 in 1.5 m 5 ft 8 in 1.7 m Height 6 ft 7 in 2m 6 ft 7 in 2m 11,500 lbs 5216 kg 10,500 lbs 4763 kg 5 3/4 in 14.6 cm 6 in 15.2 cm Machine Weight Tire size Tire ply rating Tire contact area Overall tire diameter Wheel diameter Wheel width 9-14.5 LT Tread 8 Sidewall 6 43.5 sq in 280 sq cm 28 in 37 cm 14.5 in 45 cm 7 in 18 cm Tires and wheels, Z-34/22N Tire size (solid rubber) Ground clearance 22 x 7 x 17.75 in 56 x 18 x 45 cm Load range 7600 lbs 3447 kg Tire contact area 35 sq in 226 sq cm 22 in 56 cm 17.75 in 45 cm 7 in 18 cm Platform dimensions Length 56 in 142 cm Width 30 in 76 cm 500 lbs 227 kg Overall tire diameter Wheel diameter Maximum capacity Wheel width Operational dimensions Height, platform maximum 34 ft 4 in 10.5 m 34 ft 8 in 10.6 m Wheel lugs Front Rear Height, working maximum 40 ft 4 in 12.3 m 40 ft 8 in 12.4 m Lug nut torque Horizontal reach, maximum 22 ft 4 in 6.8 m 22 ft 4 in 6.8 m 0 0 6 ft 2 in 1.9 m 6 ft 2 in 1.9 m Turning radius (outside) 12 ft 9 in 3.9 m 13 ft 1 in 4m Turning radius (inside) 6 ft 1.8 m 5 ft 8 in 1.7 m Turntable rotation (degrees) 355° 355° Platform rotation (degrees) 160° 160° 8 @ 5/8-18 9 @ 5/8-18 125 ft-lbs 169.5 Nm Fluid Capacities Turntable tailswing Wheelbase Z-34/22 before serial number 809 and Z-34/22N before serial number 1116: Hydraulic tank capacity Hydraulic system (including tank) Z-34/22 after serial number 808 and Z-34/22N after serial number 1115: Hydraulic tank capacity Hydraulic system (including tank) 5 gallons 18.9 liters 7 gallons 26.5 liters 4 gallons 15.1 liters 6 gallons 22.7 liters Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 2-1 Section 2 • Specifications First Edition • Third Printing SPECIFICATIONS Performance Specifications Drive speeds (maximum) Z-34/22 (before serial number 1734) Drive speed, stowed 4 mph 6.4 km/h 35:1 torque hubs 40 ft/6.8 sec 12.2 m/6.8 sec Drive speed, stowed 49:1 torque hubs 3.1 mph 5 km/h 40 ft/9.1 sec 12.2 m/9.1 sec (after serial number 1733) Drive speed, stowed 3.7 mph 6 km/h 47:1 torque hubs 40 ft/7.5 sec 12.2 m/7.5 sec Drive speed, 0.6 mph 1 km/h booms raised or extended 40 ft/40 sec 12.2 m/40 sec Drive speeds (maximum) Z-34/22N (before serial number 2227) Drive speed, stowed 3.4 mph 35:1 torque hubs 40 ft/8 sec Drive speed, stowed 49:1 torque hubs (after serial number 2226) Drive speed, stowed 47:1 torque hubs 5.5 km/h 12.2 m/8 sec 2.8 mph 4.5 km/h 40 ft/10 sec 12.2 m/10 sec 3.1 mph 40 ft/9 sec 5 km/h 12.2 m/9 sec Drive speed, 0.6 mph 1 km/h booms raised or extended 40 ft/40 sec 12.2 m/40 sec Gradeability (boom stowed) Z-34/22 (before serial number 1734) 49:1 drive hubs 35:1 drive hubs 35% 30% Z-34/22 (after serial number 1733) 47:1 drive hubs 30% Z-34/22N (before serial number 2227) 49:1 drive hubs 35:1 drive hubs 25% 20% Z-34/22N (after serial number 2226) 47:1 drive hubs 30% 2-2 Boom function speeds, maximum from platform controls (with 500 lbs in platform) Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227 Jib boom up 30 to 40 seconds Jib boom down 15 to 25 seconds Primary boom up 25 to 35 seconds Primary boom down 15 to 25 seconds Primary boom extend 25 to 35 seconds Primary boom retract 15 to 25 seconds Secondary boom up 15 to 25 seconds Secondary boom down 10 to 15 seconds Turntable rotate - 355° 50 to 70 seconds Platform rotate - 160° 5 to 10 seconds Platform level up 10 to 20 seconds Platform level down 10 to 20 seconds Boom function speeds, maximum from platform controls (with 500 lbs in platform) Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226 Jib boom up 23 to 29 seconds Jib boom down 20 to 26 seconds Primary boom up 15 to 21 seconds Primary boom down 12 to 18 seconds Primary boom extend 21 to 27 seconds Primary boom retract 12 to 18 seconds Secondary boom up 16 to 22 seconds Secondary boom down 12 to 18 seconds Turntable rotate - 355° 57 to 63 seconds Platform rotate - 160° 17 to 23 seconds Platform level up 10 to 20 seconds Platform level down 10 to 20 seconds Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 2 • Specifications SPECIFICATIONS Hydraulic Specifications Auxiliary pump Dexron equivalent Hydraulic fluid Displacement Lift pump Type Type Fixed displacement gear pump 0.75 gpm 2.8 l/min Fixed displacement gear pump Displacement per revolution 0.153 cu in 2.5 cc Displacement (2500 psi/172 bar) 1.6 gpm 6 l/min Hydraulic reservoir return line filter 10 micron with 25 psi (1.7 bar) bypass Function manifold Function relief valve pressure Primary boom down relief Z-34/22 (before serial number 3216) (after serial number 3215) Z-34/22N (before serial number 3767) (after serial number 3766) 3200 psi 221 bar 1400 psi 1600 psi 97 bar 110 bar 1400 psi 1600 psi 97 bar 110 bar Secondary boom down relief valve pressure 1600 psi 110 bar Primary boom extend relief valve pressure Z-34/22 (before serial number 2901) (from serial number 2901 to 3215 Z-34/22N (before serial number 3533) (from serial number 3533 to 3766) 1800 psi 124 bar 1800 psi 2800 psi 124 bar 193 bar 1800 psi 2800 psi 124 bar 193 bar Turntable rotate relief valve pressures Z-34/22 (before serial number 674) 1750 psi 121 bar (from serial number 674 to 1733) Not adjustable (after serial number 1733) 1100 psi 76 bar Z-34/22N (before serial number 935) (from serial number 935 to 2226) (after serial number 2226) Part No. 36540 1750 psi 121 bar Not adjustable 1100 psi 76 bar Genie Z-34/22 & Genie Z-34/22N 2-3 Section 2 • Specifications First Edition • Third Printing SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal-Lok® O-ring face seal fittings and hose ends. Machines that utilize Parker Seal-Lok® O-ring face seal hoses and fittings require that the fittings and hose ends be torqued to specification when they are removed and installed, or when new hoses or fittings are installed. Hydraulic Hose and Fitting Torque Specifications SAE O-ring Boss Port - tube fitting SAE Dash Installing Size into... ft. lbs. -4 Aluminum 11 Steel 16 -6 Aluminum 23 Steel 35 -8 Aluminum 40 Steel 60 -10 Aluminum 69 Steel 105 -12 Aluminum 93 Steel 140 -16 Aluminum 139 Steel 210 -20 Aluminum 172 Steel 260 -24 Aluminum 208 Steel 315 Nm 14.9 21.7 31.2 47.5 54.2 81.3 93.6 142.4 126.1 190 188.5 284.7 233.2 352.5 282 427.1 Seal-Lok® - hose end SAE Dash Size ft. lbs. -4 18 -6 27 -8 40 -10 63 -12 90 -16 120 -20 140 -24 165 Nm 24.4 36.6 54.2 85.4 122 162.7 190 223.7 Torque Procedure 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight. The O-rings used in the Parker Seal Lok® fittings and hose ends are custom size O-rings. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part number 49612). 3 Be sure that the face seal O-ring is seated and retained properly. 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight. 5 Tighten the nut or fitting to the appropriate torque per given size, as shown in the table above. 6 Operate all machine functions and inspect the hoses and fittings and related components to be sure that there are no leaks. 2 Lubricate the O-ring before installation. 2-4 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 2 • Specifications SPECIFICATIONS SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • SIZE Grade 5 THREAD LUBED 20 28 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 1/2 LUBED DRY DRY in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm 80 90 9 10.1 100 120 11.3 13.5 110 120 12.4 13.5 140 160 15.8 18 130 140 14.7 15.8 LUBED 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 A574 High Strength Black Oxide Bolts LUBED Grade 8 DRY LUBED DRY LUBED f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm 13 14 23 26 37 41 57 64 80 90 110 130 200 220 320 350 480 530 590 670 840 930 1460 1640 17.6 19 31.2 35.2 50.1 55.5 77.3 86.7 108.4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 1979 2223 17 19 31 35 49 55 75 85 110 120 150 170 270 300 430 470 640 710 790 890 1120 1240 1950 2190 23 25.7 42 47.4 66.4 74.5 101.6 115 149 162 203 230 366 406 583 637 867 962 1071 1206 1518 1681 2643 2969 18 20 33 37 50 60 80 90 120 130 160 180 280 310 450 500 680 750 970 1080 1360 1510 2370 2670 24 27.1 44.7 50.1 67.8 81.3 108.4 122 162 176 217 244 379 420 610 678 922 1016 1315 1464 1844 2047 3213 3620 25 27 44 49 70 80 110 120 150 170 210 240 380 420 610 670 910 990 1290 1440 1820 2010 3160 3560 33.9 36.6 59.6 66.4 94.7 108.4 149 162 203 230 284 325 515 569 827 908 1233 1342 1749 1952 2467 2725 4284 4826 21 24 38 43 61 68 93 105 130 140 180 200 320 350 510 560 770 840 1090 1220 1530 1700 2670 3000 28.4 32.5 51.5 58.3 82.7 92.1 126 142 176 189 244 271 433 474 691 759 1044 1139 1477 1654 2074 2304 3620 4067 METRIC FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • Class 4.6 Size (m m ) 5 6 7 LUBED DRY LUBED Class 10.9 8.8 DRY LUBED Class 12.9 10.9 DRY LUBED 12.9 DRY in- lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm 16 19 45 1.8 3.05 5.12 21 36 60 2.4 4.07 6.83 41 69 116 4.63 7.87 13.2 54 93 155 6.18 10.5 17.6 58 100 167 6.63 11.3 18.9 78 132 223 8.84 15 25.2 68 116 1.95 7.75 13.2 22.1 91 155 260 10.3 17.6 29.4 LUBED 8 10 12 14 16 18 20 22 24 Class 8.8 4.6 DRY LUBED DRY LUBED DRY LUBED DRY f t - lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm f t - lbs Nm f t - lbs Nm 5.4 10.8 18.9 30.1 46.9 64.5 91 124 157 7.41 14.7 25.6 40.8 63.6 87.5 124 169 214 7.2 14.4 25.1 40 62.5 86.2 121 166 210 9.88 19.6 34.1 54.3 84.8 117 165 225 285 14 27.9 48.6 77.4 125 171 243 331 420 19.1 37.8 66 105 170 233 330 450 570 18.8 37.2 64.9 103 166 229 325 442 562 25.5 50.5 88 140 226 311 441 600 762 20.1 39.9 69.7 110 173 238 337 458 583 27.3 54.1 94.5 150 235 323 458 622 791 26.9 53.2 92.2 147 230 317 450 612 778 36.5 72.2 125 200 313 430 610 830 1055 23.6 46.7 81 129 202 278 394 536 682 32 63.3 110 175 274 377 535 727 925 31.4 62.3 108 172 269 371 525 715 909 42.6 84.4 147 234 365 503 713 970 1233 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 2-5 Section 2 • Specifications First Edition • Third Printing This page intentionally left blank. 2-6 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 3 • Scheduled Maintenance Inspections Scheduled Maintenance Inspections Warm About This Section Tools are required New parts required The Schedule Observe and Obey: Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. Scheduled maintenance inspections shall be completed daily, hourly, quarterly, annually and every 2 years as specified on the Maintenance Inspection Report. Failure to properly complete each inspection when required could cause death, serious injury or substantial machine damage. Cold engine required engine required Dealer service suggested There are five types of maintenance inspections that must be performed according to a schedule— daily, hourly, quarterly, annual and two year. To account for repeated procedures, the Maintenance Tables and the Maintenance Inspection Report have been divided into four subsections—A, B, C, D. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection. Inspection Table or Checklist Daily Hourly and Quarterly Annual Two year A A+B A+B+C A+B+C+D Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating machine. Machines that have been out of service for a period longer than 3 months must complete the hourly and quarterly inspections. Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection. Complete step-by-step instructions for each scheduled maintenance procedure are provided in section 4, Scheduled Maintenance Procedures. Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and govermental regulations and requirements. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 3-1 Section 3 • Scheduled Maintenance Inspections First Edition • Third Printing Maintenance Tables Table A Tools are required A-1 Inspect the Operator's and Safety Manuals A-2 Inspect the Decals and Placards A-3 Inspect for Damage and Loose or Missing Parts A-4 Check the Hydraulic Oil Level A-5 Check for Hydraulic Leaks A-6 Test the Platform and Ground Controls A-7 Test the Auxiliary Power Operation A-8 Test the Tilt Sensor A-9 Test the Limit Switches A-10 Test the Lift/Drive Select Switch (if equipped) A-11 Perform 30 Day/50 Hour Service New parts required Warm engine required Cold engine required Dealer service suggested Table B B-1 Check the Batteries B-2 Inspect the Electrical Wiring B-3 Inspect the Tires and Wheels (including lug nut torque) B-4 Confirm the Proper Brake Configuration B-5 Check the Oil Level in the Drive Hubs 3-2 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 3 • Scheduled Maintenance Inspections MAINTENANCE TABLES Table B, continued Tools are required B-6 Test the Key Switch B-7 Test the Emergency Stop Buttons B-8 Test the Ground Control Override B-9 Test the Platform Self-leveling B-10 Test the Horn B-11 Test the Foot Switch B-12 Test the Drive Enable System B-13 Test the Drive Brakes B-14 Test the Drive Speed Stowed Position B-15 Test the Drive Speed Raised or Extended Position B-16 Test the Alarm Package (if equipped) B-17 Test the Turntable Rotation Stop B-18 Check the Electrical Contactors B-19 Perform Hydraulic Oil Analysis See D-1 Test or Replace the Hydraulic Oil New parts required Warm engine required Cold engine required Dealer service suggested Every 250 hours, perform the following maintenance procedure: B-20 Replace the Hydraulic Tank Return Filter Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 3-3 Section 3 • Scheduled Maintenance Inspections First Edition • Third Printing MAINTENANCE TABLES Table C Tools are required C-1 Check the Primary Boom Wear Pads C-2 Check the Turntable Rotation Bearing Bolts C-3 Check the Free-wheel Configuration C-4 Grease the Turntable Rotation Bearing and Worm Drive Gear C-5 Replace the Drive Hub Oil C-6 Bleed the Platform Rotator New parts required Warm engine required Cold engine required Dealer service suggested Table D D-1 Test or Replace the Hydraulic Oil D-2 Grease the Steer Axle Wheel Bearings 3-4 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 3 • Scheduled Maintenance Inspections Maintenance Inspection Report Model Checklist A Serial number Date Hour meter Machine owner Refer to Table A Y N R Tools are required New parts required B-9 Platform Warm levelingCold engine B-10 Horn required engine required A-1 Operator's and Safety manuals B-11 Foot switch A-2 Decals and placards B-13 Drive brakes A-3 Damage and loose or missing parts B-14 Drive speed-stowed B-12 Drive enable system B-15 Drive speed-raised A-4 Hydraulic oil level Inspected by (print) A-5 Hydraulic leaks B-16 Alarm package (if equipped) Inspector signature A-6 Platform and ground controls B-17 Turntable stop Inspector title B-18 Electrical contactors A-7 Auxiliary power B-19 Hydraulic oil analysis A-8 Tilt sensor Inspector company Instructions • Make copies of this page to use for each inspection. • Select the appropriate checklist(s) for the type of inspection to be performed. Perform quarterly or every 250 hours: A-9 Limit switches B-20 Hydraulic return filter A-10 Lift/Drive select switch (if equipped) Checklist C A-11 30 Day/50 Hour Service Y N R Refer to Table C Checklist B Y N R C-1 Boom wear pads Refer to Table B C-2 Turntable bearing bolts Daily Inspection: A B-1 Batteries C-3 Free-wheel configuration Hourly/Quarterly Inspection: A+B B-2 Electrical wiring C-4 Grease rotation bearing B-3 Tires and wheels C-5 Drive hub oil Annual Inspection: A+B+C B-4 Brake configuration C-6 Platform rotator 2 Year Inspection: A+B+C+D B-5 Drive hub oil level • Place a check in the appropriate box after each inspection procedure is completed. • Use the maintenance tables in this section and the step-by-step procedures in section 4 to learn how to perform these inspections. Dealer service suggested B-6 Key switch B-7 Emergency stop B-8 Ground control override Checklist D Y N R Refer to Table D D-1 Hydraulic oil D-2 Wheel bearings • If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 3-5 Section 3 • Scheduled Maintenance Inspections First Edition • Third Printing Tools are required New parts required Warm engine required Cold engine required Dealer service suggested This page intentionally left blank. 3-6 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions. Observe and Obey: Symbols Legend Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. Scheduled maintenance inspections shall be completed daily, hourly, quarterly, annually and every 2 years as specified on the Maintenance Inspection Report. Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Failure to properly complete each inspection when required may cause death, serious injury or substantial machine damage. Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating machine. Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Unless otherwise specified, perform each procedure with the machine in the following configuration: • Machine parked on a flat level surface Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. • Boom in the stowed position • Turntable rotated with the boom between the non-steering wheels • Key switch in the OFF position with the key removed Green—used to indicate operation or maintenance information. • Wheels chocked Indicates that a specific result is expected after performing a series of steps. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4-1 Section 4 • Scheduled Maintenance Procedures First Edition • Third Printing Table A Procedures A-1 Inspect the Operator’s and Safety Manuals A-2 Inspect the Decals and Placards Maintaining the operator’s and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition. Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions. 1 Check to be sure the storage container is present and in good condition. 2 Check to make sure that the operator’s, responsibilities and safety manuals are present and complete in the storage container in the platform. 3 Examine the pages of each manual to be sure that they are legible and in good condition. 1 Refer to the Decals section in the Genie Z-34/22 & Genie Z-34/22N Operator's Manual and use the decal list and illustrations to determine that all decals and placards are in place. 2 Inspect all decals for legibility and damage. Replace any damaged or illegible decal immediately. 4 Always return the manuals to the storage container after use. Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed. 4-2 Genie Z-34/22 & Genie Z-34/22N Contact your authorized Genie distributor or Genie Industries if replacement decals are needed. Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE A A-3 Inspect for Damage and Loose or Missing Parts PROCEDURES A-4 Check the Hydraulic Oil Level Daily machine condition inspections are essential to safe machine operation and good machine performance. Failure to locate and repair damage, and discover loose or missing parts may result in an unsafe operating condition. Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic oil levels can damage hydraulic components. Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems. 1 Inspect the entire machine for damage and improperly installed or missing parts including: Z-34/22 before serial number 572 and Z-34/22N before serial number 572: • Electrical components, wiring and electrical cables • Hydraulic power units, reservoir, hoses, fittings, cylinders and manifolds • Drive and turntable motors and drive hubs. • Boom wear pads 1 Be sure that the boom is in the stowed position. 2 Remove the breather cap with dipstick from the hydraulic tank. 3 Visually inspect the dipstick. Result: The hydraulic oil level should be at the FULL mark on the dipstick. • Tires and wheels Z-34/22 from serial number 572 to 808 and Z-34/22N from serial number 572 to 1115: • Limit switches, alarms and horn • Nuts, bolts and other fasteners • Platform entry mid-rail/gate • Beacon and alarms (if equipped) Check entire machine for: • Cracks in welds or structural components 1 Be sure that the boom is in the stowed position, then visually inspect the sight glass on the hydraulic tank. Result: The hydraulic oil level should be within the top and bottom of the sight glass. • Dents or damage to machine • Battery packs and connections • Compartment covers and latches Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4-3 Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES Z-34/22 after serial number 808 and Z-34/22N after serial number 1115: A-5 Check for Hydraulic Leaks 1 Be sure that the boom is in the stowed position. 2 Visually inspect the hydraulic tank. Result: The hydraulic oil level should be within the FULL and ADD marks on the hydraulic tank. Hydraulic Oil Specifications Hydraulic oil type Dexron equivalent Z-34/22 before serial number 809 and Z-34/22N before serial number 1116: Hydraulic tank capacity Hydraulic system (including tank) Z-34/22 after serial number 808 and Z-34/22N after serial number 1115: Hydraulic tank capacity Hydraulic system (including tank) 4-4 First Edition • Third Printing Detecting hydraulic fluid leaks is essential to operational safety and good machine performance. Undiscovered leaks can develop into hazardous situations, impair machine functions and damage machine components. 1 Inspect for hydraulic oil puddles, dripping or residue on or around the following areas: • Hydraulic tank—filter, fittings, hoses and turntable surface 5 gallons 18.9 liters 7 gallons 26.5 liters • Compartments—hydraulic power unit, auxiliary power unit, pumps, suction filter, fittings, hoses, and turntable surface • All hydraulic cylinders • All hydraulic manifolds 4 gallons 15.1 liters 6 gallons 22.7 liters • Primary, secondary and jib booms • The underside of the turntable • The underside of the drive chassis • Ground area under the machine Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES 4 Turn the key switch to platform controls and pull out the Emergency Stop button to the ON position at both the ground and platform controls. A-6 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation. An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions. Each function should operate smoothly and be free of hesitation, jerking and unusual noise. Z-34/22N before serial number 304 and Z-34/22 before serial number 153: 1 Turn the key switch to ground controls and pull out the Emergency Stop button to the ON position at both the ground and platform controls. Result: Beacon (if equipped) should flash. 5 Move the lift/drive select toggle switch to the lift position (if equipped). 6 Press down the foot switch and operate each machine function through a full cycle. Result: All machine functions should operate smoothly. 7 Push in the Emergency Stop button to the OFF position. Result: No function should operate. The machine should stop. Result: Beacon (if equipped) should flash. 2 Attempt to activate each boom and platform function toggle switch. Result: All machine functions should operate through a full cycle. The descent alarm (if equipped) should sound while the boom is lowering. 3 Push in the Emergency Stop button to the OFF position. As a safety feature, selecting and operating the ground controls will override the platform controls, including the Emergency Stop button. Machines equipped with Platform Level Control Disable Function: The platform level toggle switch will not operate when the primary boom is raised past the drive speed limit switch. Result: No function should operate. The machine should stop. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4-5 Section 4 • Scheduled Maintenance Procedures TABLE A First Edition • Third Printing PROCEDURES Z-34/22N after serial number 303 and Z-34/22 and after serial number 152: 1 Turn the key switch to ground controls and pull out the Emergency Stop button to the ON position at both the ground and platform controls. Result: Beacon (if equipped) should flash. 2 Do not hold the function enable switch to either side. Attempt to activate each boom and platform function toggle switch. Result: All boom and platform functions should not operate. 3 Hold the function enable switch to either side and activate each boom and platform function toggle switch. 5 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and the platform controls. Result: Beacon (if equipped) should flash. 6 Press down the foot switch and operate each machine function through a full cycle. Result: All machine functions should operate smoothly. 7 Push in the Emergency Stop button to the OFF position. Result: No function should operate. The machine should stop. Result: All machine functions should operate through a full cycle. The descent alarm (if equipped) should sound while the boom is lowering. As a safety feature, selecting and operating the ground controls will override the platform controls, including the Emergency Stop button. Machines equipped with Platform Level Control Disable Function: The platform level toggle switch will not operate when the boom is raised past the drive speed limit switch. 4 Push in the Emergency Stop button to the OFF position. Result: No function should operate. The machine should stop. 4-6 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE A A-7 Test the Auxiliary Power Operation Detection of auxiliary power system malfunctions is essential for safe machine operation. An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss. Auxiliary power is designed for short term emergency use only. Excessive use will result in battery drain and component damage. PROCEDURES 6 Lift the red auxiliary power switch cover. 7 Simultaneously hold the auxiliary power switch ON while activating each function through a partial cycle. Result: Each function should operate smoothly. 1 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. 2 Lift the red auxiliary power switch cover. 3 Simultaneously hold the auxiliary power switch in the ON direction while activating each function through a partial cycle. Result: Each function should operate smoothly. 4 Turn the key switch to platform control. 5 At the platform controls, pull out the Emergency Stop button to the ON position, then press down the foot switch. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4-7 Section 4 • Scheduled Maintenance Procedures TABLE A First Edition • Third Printing PROCEDURES A-8 Test the Tilt Sensor A-9 Test the Limit Switches The tilt sensor sounds an alarm in the platform when the incline of the machine exceeds the rating on the serial plate. Detecting limit switch malfunctions is essential to safe machine operation. The drive limit switch is used to restrict drive speed when the boom is raised or extended. The drive enable limit switch activates a signal light to inform the operator that the platform is over the steering wheels, and stops drive movement unless the drive enable override switch is used. Improperly functioning limit switches will allow the boom to raise and/or drive into an unsafe position. Select a level test area. The tilt alarm should not be sounding prior to test. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 2 Open the ground control side turntable cover and press down on one side of the tilt sensor. Hold for 5 seconds. Result: The alarm located in the platform should sound. Tip-over hazard. The alarm should be heard at the ground controls. If you can't hear the alarm at the ground controls, replace the alarm in the platform. Drive Speed Limit Switches 1 With the boom in the stowed position, visually inspect the drive speed limit switches for the following: • Broken or missing rollers or arms • Missing fasteners • Loose wiring a b d c 4-8 Genie Z-34/22 & Genie Z-34/22N a primary boom drive speed limit switch (LS2) (Z-34/22 after serial number 367 and Z-34/22N after serial number 540) b boom extend drive speed limit switch (LS1) c secondary boom drive speed limit switch (LS4) (Z-34/22 after serial number 366 and Z-34/22N after serial number 539) d primary/secondary boom drive speed limit switch (LS2) (Z-34/22 before serial number 367 and Z-34/22N before serial number 540) Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE A 2 Extend the primary boom approximately 12 inches (30 cm). 3 Manually activate the boom extend drive speed limit switch. Result: The drive speed limit switch arm should move freely and spring return to center. A distinct click should be felt and heard. 4 Fully retract the primary boom. 5 Z-34/22 and Z-34/22N machines manufactured before May, 1999: Remove the rear turntable cover mounting fasteners, then remove the cover. Manually activate the secondary boom drive speed limit switch. Z-34/22 and Z-34/22N machines manufactured after April, 1999: Manually activate the secondary boom drive speed limit switch. Result: The drive speed limit switch arm should move freely and spring return to center. A distinct click should be felt and heard. 6 Manually activate the primary boom drive limit switch. Result: The drive speed limit switch arm should move freely and spring return to center. A distinct click should be felt and heard. PROCEDURES 8 Press down the foot switch and slowly move the drive control handle off center. Result: The machine should move at normal drive speeds. 9 Raise the primary boom approximately 5 feet (1.5 m). 10 Slowly move the drive control handle off center. Result: The machine should move at a reduced drive speed. 11 Lower the primary boom to the stowed position. 12 Raise the secondary boom approximately 5 feet (1.5 m). 13 Slowly move the drive control handle off center. Result: The machine should move at a reduced drive speed. 14 Lower the secondary boom to the stowed position. 15 Extend the primary boom 12 inches (30 cm). 16 Slowly move the drive control handle off center. Result: The machine should move at a reduced drive speed. Raised Drive speed (maximum) Platform raised 40 ft/40 sec 12.2 m/40 sec 7 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at the platform controls. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4-9 Section 4 • Scheduled Maintenance Procedures TABLE A First Edition • Third Printing PROCEDURES 6 Manually activate the drive enable limit switch. Drive Enable Limit Switch 1 With the boom in the stowed position, visually inspect the drive enable limit switch for the following: Result: The drive enable limit switch roller should move freely and spring return to center. A distinct click should be felt and heard. • Broken or missing roller or arm a • Missing fasteners • Loose wiring b 2 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. c d 3 At the platform controls, rotate the turntable to the left until the primary boom is past the left non-steer wheel. Result: The drive enable indicator light should be ON. a b c d swing chassis limit switch cam drive enable limit switch (LS3) drive chassis 4 Move the drive control handle off center. Result: The drive function should not operate. 5 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center. Result: The drive function should operate. 4 - 10 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE A A-10 Test the Lift/Drive Select Switch (if equipped) 1 Move the lift/drive select switch to the lift position. 2 Press down the foot switch and move the drive control handle off center. Result: No drive functions should operate. 3 Activate each boom function toggle switch. Result: All boom functions should operate. 4 Move the lift/drive select switch to the drive position. PROCEDURES A-11 Perform 30 Day/50 hour Service The 30 day maintenance procedure is a onetime sequence of procedures to be performed after the first 30 days or 50 hours of usage. After this interval, refer to the maintenance tables for continued scheduled maintenance. 1 Perform the following maintenance procedures: • B-3 Inspect Tires and Wheels (including lug nut torque) • B-20 Replace the Hydraulic Tank Return Filter • C-2 Check the Turnable Rotation Bearing Bolts 5 Press down the foot switch and activate each boom function toggle switch. Result: No boom functions should operate. 6 Move the drive control handle off center. Result: The drive functions should operate. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4 - 11 Section 4 • Scheduled Maintenance Procedures First Edition • Third Printing Table B Procedures 5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. Electrocution/burn hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Result: If any battery cell displays a specific gravity of less than 1.026, the battery must be replaced. 6 Check the battery acid level of the battery. If needed, replenish with distilled water to the bottom of the battery fill tube. Do not overfill. 7 Install the battery vent caps. 8 Check each battery pack and verify that the batteries are wired correctly. 9 Connect the battery packs to the machine. + Perform this test after fully charging the batteries. - 1 Put on protective clothing and eye wear. - - + Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. + B-1 Check the Batteries 2 Disconnect the battery packs from the machine. - + + - 3 Be sure the battery cable connections are free of corrosion. 4 Be sure the battery hold down and cable connections are tight. 4 - 12 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE B B-2 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage. PROCEDURES 5 Lower the boom to the stowed position and turn the machine off. 6 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: • Cable track on the primary boom • Primary boom to platform cable harness • Inside of the platform control box Electrocution/burn hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Inspect the following areas for burnt, chafed, corroded and loose wires: • Electrical power panel • Electrical relay panel • Ground control panel • Turntable manifold wiring 2 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. 3 Raise the secondary boom until the lower mid-pivot is approximately 10 feet (3 m) off the ground. 4 Inspect the turntable center area for burnt, chafed and pinched cables. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4 - 13 Section 4 • Scheduled Maintenance Procedures TABLE B First Edition • Third Printing PROCEDURES B-3 Inspect the Tires and Wheels (including lug nut torque) B-4 Confirm the Proper Brake Configuration Maintaining the tires and wheels in good condition is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion. Proper brake configuration is essential to safe operation and good machine performance. Hydraulically-released, spring-applied individual wheel brakes can appear to operate normally when they are actually not fully operational. 1 Check the tire surface and sidewalls for cuts, cracks, and unusual wear. 1 Check each drive hub disconnect cap to be sure it is in the engaged position. 2 Check each wheel for damage, bends and cracked welds. brake disengage position 3 Check each lug nut for proper torque. brake engage position Tires and wheels Lug nut torque, dry Lug nut torque, lubricated 4 - 14 125 ft-lbs 95 ft-lbs 169.5 Nm 129 Nm Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-5 Check the Oil Level in the Drive Hubs 4 Apply pipe thread sealant to the plugs and install the plugs into the hub. Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage. Drive Hub Oil 5 Repeat this procedure for each drive hub. 1 Drive the machine to rotate the hub until one of the plugs is located on top and the other is at 90 degrees. Capacity (before serial number 1734) 49:1 and 35:1 models 17 fluid ounces 0.5 liters (after serial number 1733) 47:1 models 25.6 fluid ounces 0.76 liters Type: SAE 90 multipurpose hypoid gear oil - API service classification GL5 2 Remove the plug located at 90 degrees and check the oil level. Result: The oil level should be even with the bottom of the plug hole. 3 If necessary, remove the top plug and add oil until the oil level is even with the bottom of the side plug hole. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4 - 15 Section 4 • Scheduled Maintenance Procedures TABLE B First Edition • Third Printing PROCEDURES B-6 Test the Key Switch B-7 Test the Emergency Stop Buttons Proper key switch action and response is essential to safe machine operation. The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch. Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation. Properly functioning Emergency Stop buttons are essential for safe machine operation. An improperly operating Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation. As a safety feature, selecting and operating the ground controls will override the platform controls, including the Emergency Stop button. 1 Pull out the Emergency Stop button to the ON position at both the ground and platform controls. 2 Turn the key switch to platform control. 3 Check the machine functions from the ground controls. Result: The machine functions should not operate. 4 Turn the key switch to ground control. 5 Check the machine functions from the platform controls. Result: The machine functions should not operate. 6 Turn the key switch to the OFF position. Result: No function should operate. The machine should stop. 1 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. 2 Push down the Emergency Stop button to the OFF position. Result: No functions should operate. The machine should stop. 3 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 4 Push down the platform Emergency Stop button to the OFF position. Result: No machine functions should operate. The ground Emergency Stop button will stop all machine operation, even if the key switch is switched to platform control. 4 - 16 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-8 Test the Ground Control Override B-9 Test the Platform Self-leveling A properly functioning ground control override is essential to safe machine operation. The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether the Emergency Stop button on the platform controls is in the ON or OFF position. This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position. Automatic platform self-leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation. The platform is maintained at level by the platform leveling slave cylinder which is controlled by the master cylinder located at the base of the primary boom. A platform self-leveling failure creates an unsafe working condition. 1 Push down the platform Emergency Stop button to the OFF position. 2 Turn the key switch to ground control and pull out the ground controls Emergency Stop button to the ON position. 3 Operate each boom function through a partial cycle at the ground controls. Result: All boom functions should operate. Part No. 36540 1 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. 2 Lower the boom to the stowed position. 3 Adjust the platform to a level position using the platform leveling toggle switch. 4 Raise and lower the primary boom through a full cycle. Result: The platform should remain level at all times to within ±5 degrees. Genie Z-34/22 & Genie Z-34/22N 4 - 17 Section 4 • Scheduled Maintenance Procedures TABLE B First Edition • Third Printing PROCEDURES B-10 Test the Horn B-11 Test the Foot Switch A properly functioning horn is essential to safe machine operation. The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel. An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions. A properly functioning foot switch is essential to safe machine operation. Machine functions should activate and operate smoothly as long as the foot switch is pressed down, and promptly stop when the foot switch is released. An improperly functioning foot switch can cause an unsafe working condition. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 2 Push down the horn button at the platform controls. 2 Without pressing down the foot switch, attempt to operate the machine functions. Result: The horn should sound. If necessary, the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn. 4 - 18 Result: The machine functions should not operate. 3 Press down the foot switch and operate the machine functions. Result: The machine functions should operate. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-12 Test the Drive Enable System 4 Move the drive control handle off center. Proper drive enable system operation is essential to safe machine operation. When the primary boom is past the non-steering wheels, drive movement is stopped and the indicator light turns on. The drive enable toggle switch must be used to reactivate drive function and should inform the operator that the machine may move in the opposite direction that the drive and steer controls are moved. An improperly functioning drive enable system may allow the machine to be moved into an unsafe position. 5 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 2 At the platform controls, rotate the turntable to the right until the primary boom is past the right non-steer wheel. Result: The drive function should not operate. Result: The drive function should operate. Collision hazard. Always use the color-coded direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel. 6 Rotate the turntable to the left until the primary boom is past the left-steer wheel. Result: The drive enable indicator light should come on. 7 Repeat steps 3 through 5. Result: The drive enable indicator light should come on and remain on while the boom is past the non-steer wheel. 3 Move the lift/drive select switch to the drive position. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4 - 19 Section 4 • Scheduled Maintenance Procedures TABLE B First Edition • Third Printing PROCEDURES B-13 Test the Drive Brakes Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise. Hydrostatic brakes and hydraulicallyreleased individual wheel brakes can appear to operate normally when not fully operational. 6 Bring the machine to maximum drive speed before reaching the test line. Release the drive joystick when your reference point on the machine crosses the test line. 7 Measure the distance between the test line and your machine reference point. Braking: paved surface Stopping distance Collision hazard. Be sure that the machine is not in free-wheel or partial free-wheel configuration. Refer to B-4 in this section, Confirm the Proper Brake Configuration. 3 to 4 ft 0.9 to 1.2 m The brakes must be able to hold the machine on any slope it is able to climb. Select a test area that is firm, level and free of obstructions. 1 Mark a test line on the ground for reference. 2 Lower the boom into the stowed position. 3 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 4 Move the lift/drive switch to the DRIVE position (if equipped). 5 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the test line. 4 - 20 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-14 Test the Drive Speed Stowed Position 6 Bring the machine to maximum drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. 7 Continue at full speed and note the time when the machine reference point passes over the finish line. Select a test area that is firm, level and free of obstructions. 1 Create start and finish lines by marking two lines on the ground 40 feet (12.2 m) apart. 2 Lower the boom into the stowed position. 3 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 4 Move the lift/drive switch to the DRIVE position (if equipped). 5 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. Part No. 36540 Drive speeds (maximum) Z-34/22 (before serial number 1734) Drive speed, stowed 4 mph 6.4 km/h 35:1 torque hubs 40 ft/6.8 sec 12.2 m/6.8 sec Drive speed, stowed 49:1 torque hubs 3.1 mph 5 km/h 40 ft/9.1 sec 12.2 m/9.1 sec (after serial number 1733) Drive speed, stowed 3.7 mph 6 km/h 47:1 torque hubs 40 ft/7.5 sec 12.2 m/7.5 sec Drive speeds (maximum) Z-34/22N (before serial number 2227) Drive speed, stowed 3.4 mph 35:1 torque hubs 40 ft/8 sec Drive speed, stowed 49:1 torque hubs (after serial number 2226) Drive speed, stowed 47:1 torque hubs Genie Z-34/22 & Genie Z-34/22N 5.5 km/h 12.2 m/8 sec 2.8 mph 4.5 km/h 40 ft/10 sec 12.2 m/10 sec 3.1 mph 40 ft/9 sec 5 km/h 12.2 m/9 sec 4 - 21 Section 4 • Scheduled Maintenance Procedures TABLE B First Edition • Third Printing PROCEDURES B-15 Test the Drive Speed Raised or Extended Position 6 Bring the machine to maximum drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. 7 Continue at full speed and note the time when the machine reference point passes over the finish line. Select a test area that is firm, level and free of obstructions. Drive speeds (maximum): raised or extended position Drive speed, raised or extended 0.6 mph 1 km/h 40 ft/40 sec 12.2 m/40 sec 1 Create start and finish lines by marking two lines on the ground 40 feet (12.2 m) apart. 2 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 3 Raise the primary boom more than 5 feet (1.5 m). 4 Move the lift/drive switch to the DRIVE position (if equipped). 5 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 4 - 22 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE B B-16 Test the Alarm Package (if equipped) The alarm package includes: • Travel alarm • Descent alarm • Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion. The alarm package is installed on the ground controls side turntable cover. 1 Turn the key switch to ground control and pull out the Emergency Stop buttons to the ON position. Result: The flashing beacon should be ON and flashing. 2 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the primary boom toggle switch to the down position, hold for a moment and then release it. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side. Move the primary boom toggle switch to the down position, hold for a moment and then release it. Part No. 36540 PROCEDURES 3 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the secondary boom toggle switch to the DOWN position, hold for a moment and then release it. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side. Move the secondary boom toggle switch to the DOWN position, hold for a moment and then release it. 4 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the jib boom toggle switch to the DOWN position, hold for a moment and then release it. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side. Move the jib boom toggle switch to the DOWN position, hold for a moment and then release it. Result: The descent alarm should sound when each control toggle switch is held down. 5 Turn the key switch to platform control. Genie Z-34/22 & Genie Z-34/22N 4 - 23 Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES 6 At the platform controls pull out the Emergency Stop button to the ON position. Result: The flashing beacon should be on and flashing. 6 Move the lift/drive switch to the LIFT position (if equipped). 7 Press down the foot switch. Move the primary boom toggle switch to the DOWN position, hold for a moment and then release it. Move the secondary boom toggle switch to the DOWN position, hold for a moment and then release it. Move the jib boom toggle switch to the DOWN position, hold for a moment and then release it. Result: The descent alarm should sound when each control toggle switch is held down. 8 Move the lift/drive switch to the DRIVE position (if equipped). 9 Press down the foot switch. Move the drive control handle off center, hold for a moment and then release it. Move the drive control handle off center in the opposite direction, hold for a moment and then release it. Result: The travel alarm should sound when the drive control handle is moved off center in either direction. 4 - 24 First Edition • Third Printing B-17 Test the Turntable Rotation Stop The turntable is capable of rotating the boom 355 degrees and is stopped midpoint between the steering wheels by the rotation stop. Detecting a rotation stop malfunction is essential to safe operation and good machine performance. If the turntable rotates past the rotation stop, component damage may result. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both ground and platform controls. 2 Move the lift/drive switch to the LIFT position (if equipped). 3 Rotate the turntable to the left as far as it will go. Result: Movement should stop when the primary boom reaches midpoint between the steer tires. 4 Rotate the turntable to the right full circle as far as it will go. Result: Movement should stop when the primary boom reaches midpoint between the steer tires. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES B-18 Check the Electrical Contactors B-19 Perform Hydraulic Oil Analysis Maintaining the electrical contactors in good condition is essential to safe machine operation. Failure to locate a worn or damaged contactor could result in an unsafe working condition and component damage. See D-1, Test or Replace the Hydraulic Oil. 1 Remove the non-steer drive chassis cover and locate the electrical contactors mounted on the component mounting panel. 2 Visually inspect the contact points of each contactor for the following items: • Excessive burns • Excessive arcs • Excessive pitting Electrocution/burn hazard. Contact with hot or live circuits could cause death or serious injury. Remove all rings, watches and other jewelry. Replace the contactors if any damage is found. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4 - 25 Section 4 • Scheduled Maintenance Procedures TABLE B First Edition • Third Printing PROCEDURES B-20 Replace the Hydraulic Tank Return Filter Genie requires that this procedure be performed quarterly or every 250 hours, whichever comes first. Perform this procedure more often if dusty conditions exist. Replacement of the hydraulic return filter is essential for good machine performance and service life. A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. The hydraulic return filter is located on the bulkhead next to the hydraulic power unit. Z-34/22 before serial number 810 and Z-34/22N before serial number 1117: 1 Clean the area around the oil filter housing, then remove the filter with an oil filter wrench. 4 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Turn the key switch to ground controls and pull out the Emergency Stop button to the ON position. Move the primary boom up toggle switch in the UP direction. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Turn the key switch to ground controls and pull out the Emergency Stop button to the ON position. Hold the function enable toggle switch to either side and move the primary boom up toggle switch in the UP direction. 5 Inspect the filter and related components to be sure that there are no leaks. Clean up any oil that may have spilled during the replacement procedure. Properly discard the oil. Z-34/22 after serial number 809 and Z-34/22N after serial number 1116: 1 Clean the area around the oil filter housing located on top of the tank. 2 Remove the oil filter housing cover fasteners, then remove the cover. 3 Remove the oil filter element from the housing. 4 Clean the oil filter housing with a mild solvent. 2 Apply a thin layer of fresh oil to the gasket on the new oil filter. Install the new filter. 3 Tighten it securely by hand. 4 - 26 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE B PROCEDURES 5 Install the new oil filter element. 6 Install the oil filter housing cover and tighten the fasteners. 7 Turn the key switch to ground controls and pull out the Emergency Stop button to the ON position. Hold the function enable toggle switch to either side and move the primary boom up toggle switch in the UP direction. 8 Inspect the filter and related components to be sure that there are no leaks. Clean up any oil that may have spilled during the replacement procedure. Properly discard the oil. Oil filters - Genie part numbers Z34/22 before serial number 431 from serial number 431 to 809 from serial number 810 to 2265 from serial number 2266 to 3110 after serial number 3110 45087 44788 58995 74346 74634 Z34/22N before serial number 1117 from serial number 1117 to 3032 from serial number 3033 to 3659 after serial number 3660 44788 58995 74346 74634 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4 - 27 Section 4 • Scheduled Maintenance Procedures First Edition • Third Printing Table C Procedures C-1 Check the Primary Boom Wear Pads C-2 Check the Turntable Rotation Bearing Bolts Maintaining the primary boom wear pads in good condition is essential to safe machine operation. Wear pads are placed on boom tube surfaces to provide a low friction, replaceable wear pad between moving parts. Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions. Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation. Improper bolt torque could result in an unsafe operating condition and component damage. 1 Raise the secondary boom and place a safety chock on the secondary boom lift cylinder. Carefully lower the boom onto the lift cylinder safety chock. 1 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. 2 Extend the primary boom approximately 10 inches (25 cm). 3 Measure each wear pad. Replace the wear pad if it is less than 0.41 inches (1 cm) thick. If the wear pad is more than 0.41 inches (1 cm) thick, see 4-2, How to Shim the Primary Boom, in the Repair Section. Crushing hazard. Keep hands away from the cylinder and all moving parts when lowering the secondary boom. The lift cylinder safety chock is available from Genie Industries (Genie part number 36555). 4 Extend and retract the primary boom through the entire range of motion to check for tight spots that could cause binding or scraping. Always maintain squareness between the primary boom outer and inner tubes. 4 - 28 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE C 2 Check to ensure that each turntable bearing bolt is torqued in specified order to 190 ft-lbs (258 Nm). PROCEDURES 5 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in specified order to 190 ft-lbs (258 Nm). Bolt torque sequence Z-34/22 before serial number 1735 and Z-34/22N before serial number 2240 Bolt torque sequence Z-34/22 before serial number 1735 and Z-34/22N before serial number 2240 Bolt torque sequence Z-34/22 after serial number 1734 and Z-34/22N after serial number 2239 Bolt torque sequence Z-34/22 after serial number 1734 and Z-34/22N after serial number 2239 3 Raise boom and remove the safety chock. Lower the boom to the stowed position. 4 Swing out the battery packs to expose the turntable bearing bolt access hole. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4 - 29 Section 4 • Scheduled Maintenance Procedures TABLE First Edition • Third Printing C PROCEDURES 5 Manually rotate each non-steering wheel. C-3 Check the Free-wheel Configuration Result: Each non-steering wheel should rotate with minimum effort. Proper use of the free-wheel configuration is essential to safe machine operation. The free-wheel configuration is used primarily for towing. A machine configured to free-wheel without operator knowledge may cause death or serious injury and property damage. 6 Engage the drive hubs by turning over the drive hub disconnect caps. Carefully remove the jack stands, lower the machine and remove the jack. Collision hazard. Select a work site that is firm and level. Collision hazard. Failure to engage the drive hubs could cause death or serious injury and property damage. Component damage hazard. If the machine must be towed, do not exceed 2 mph (3.2 km/h). 1 Chock the steer wheels to prevent the machine from rolling. 2 Center a lifting jack of ample capacity (15000 lbs/6804 kg) under the drive chassis between the non-steering wheels. 3 Lift the wheels off the ground and then place jack stands under the drive chassis for support. 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steering wheel hub. brake disengage position brake engage position 4 - 30 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE C C-4 Grease the Turntable Rotation Bearing and Worm Drive Gear Yearly application of lubrication to the turntable bearing and worm drive gear is essential to good machine performance and service life. Continued use of an improperly greased gear will result in component damage. 1 Locate the grease fitting mounted on the bulkhead next to the hydraulic power unit. 2 Pump grease into the turntable rotation bearing. Rotate the turntable in increments of 4 to 5 inches (10 to 13 cm) at a time and repeat this step until the entire bearing has been greased. PROCEDURES C-5 Replace the Drive Hub Oil Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage. 1 Select the drive hub to be serviced. Drive the machine until one of the two plugs is at the lowest point. 2 Remove both plugs and drain the oil. 3 Drive the machine until one plug is at the top and the other is at 90 degrees. 3 Locate the 3 grease fittings on the worm drive housing. a b a b grease fittings grease overflow 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole. 4 Pump grease into the gear until you see it coming out of the side of the gear housing. Lubricant Type Part No. 36540 Multipurpose grease Genie Z-34/22 & Genie Z-34/22N 4 - 31 Section 4 • Scheduled Maintenance Procedures TABLE First Edition • Third Printing C PROCEDURES 5 Apply pipe thread sealant to the plugs, then install the plugs. 6 Repeat this procedure for each drive hub. Drive Hub Oil Capacity (before serial number 1734) 49:1 and 35:1 models 17 fluid ounces 0.5 liters (after serial number 1733) 47:1 models 25.6 fluid ounces 0.76 liters C-6 Bleed the Platform Rotator See Repair procedure 2-3, How to Bleed the Platform Rotator. Type: SAE 90 multipurpose hypoid gear oil - API service classification GL5 4 - 32 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures Table D Procedures D-1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often. The machine uses Dexron equivalent hydraulic oil. Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. 2 Completely drain the tank into a suitable container. See capacity specifications. 3 Remove the suction strainer and the magnet and then clean the tank with mild solvent. 4 Install the suction strainer. 5 Place the magnet inside the tank and install the tank on the power unit. 6 Fill the tank with hydraulic oil until the level is within the top 2 inches (5 cm) of the hydraulic oil decal. Do not overfill. 7 Clean up any oil that may have spilled. Z-34/22 after serial number 808 and Z-34/22N after serial number 1115: 1 Close the hydraulic shut-off valve located at the hydraulic tank. Component damage hazard. The machine must not be operated with the hydraulic tank shut-off valve in the CLOSED position or component damage will occur. If the tank valve is closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Perform this procedure with the boom in the stowed position. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 2 Place a suitable container under the hydraulic tank. See capacity specifications. Z-34/22 before serial number 809 and Z-34/22N before serial number 1116: 1 Remove the tank mounting fasteners. Remove the tank from the power unit. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4 - 33 Section 4 • Scheduled Maintenance Procedures TABLE First Edition • Third Printing D PROCEDURES 3 Disconnect and plug the hydraulic hose from the hydraulic tank shut-off valve. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Open the valve on the hydraulic tank and drain the oil into a suitable container. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 5 Tag, disconnect and plug the hydraulic hoses from the hydraulic tank filter. Cap the fittings on the filter. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 8 Remove the tank lid retaining fasteners and remove the lid and filter assembly from the tank. 9 Remove the suction strainer from the tank and clean with a mild solvent 10 Rinse out the inside of the tank with a mild solvent. 11 Install the lid and filter assembly onto the hydraulic tank. 12 Install the suction strainer using a thread sealant on the threads. 13 Install the hydraulic tank on the machine. Install the hydraulic tank mounting fasteners and torque to 5 ft-lbs (6.8 Nm). Component damage hazard. The hydraulic tank may become damaged if the tank mounting fasteners are over tightened. 14 Install the hydraulic hoses. 15 Fill the tank with hydraulic oil until the fluid is within the FULL and ADD marks on the hydraulic tank. Do not overfill. 16 Clean up any oil that may have spilled. Properly discard the oil. 17 Open the hydraulic tank shut-off valve. 6 Remove the hydraulic tank mounting fasteners. 7 Remove the hydraulic tank from the machine. 4 - 34 Genie Z-34/22 & Genie Z-34/22N Component damage hazard. Be sure to open the hydraulic tank shut-off valve after installing the hydraulic tank. Part No. 36540 First Edition • Third Printing Section 4 • Scheduled Maintenance Procedures TABLE D 18 Operate all machine functions through a full cycle and check for leaks. 19 Check oil level. Torque specification 1 /4 -20 fasteners 5 ft-lbs 6.8 Nm Hydraulic Oil Specifications Z-34/22 before serial number 809 and Z-34/22N before serial number 1116: Hydraulic tank capacity 5 gallons 18.9 liters Hydraulic system (including tank) 26.5 liters 7 gallons PROCEDURES D-2 Grease the Steer Axle Wheel Bearings Maintaining the steer axle wheel bearings is essential for safe machine operation and service life. Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage. Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often. 1 Loosen the wheel lug nuts. Do not remove them. Z-34/22 after serial number 808 and Z-34/22N after serial number 1115: Hydraulic tank capacity 4 gallons 15.1 liters Hydraulic system (including tank) 2 Block the non-steering wheels, then center a lifting jack under the steer axle. 22.7 liters 3 Raise the machine approximately 6 inches (15 cm) and place blocks under the drive chassis for support. 6 gallons 4 Remove the lug nuts, then remove the tire and wheel assembly. 5 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and down. Result: There should be no side to side or up and down movement. Skip to step 9 if there is no movement. 6 Remove the dust cap from the hub, then remove the cotter pin from the castle nut. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 4 - 35 Section 4 • Scheduled Maintenance Procedures TABLE First Edition • Third Printing D PROCEDURES 7 Tighten the castle nut to 35 ft-lbs (47 Nm). 15 Slide the hub onto the yoke spindle. 8 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and down. Result: If there is no side to side or up and down movement, proceed to step 9 to replace the wheel bearings with new ones. When replacing a wheel bearing, both the inner and outer bearings, including the pressed-in races, must be replaced. Result: If there is no side to side or up and down movement, grease the wheel bearings. Component damage hazard. Do not apply excessive force or damage to the lip of the seal may occur. 16 Place the outer bearing into the hub. 17 Install the washer and castle nut. 18 Tighten the castle nut to 35 ft-lbs (47 Nm) to seat the bearings. 19 Loosen the castle nut, then tighten to 8 ft-lbs (11 Nm). 20 Install a new cotter pin. Bend the cotter pin to lock it in place. Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut. 9 Remove the castle nut. Always replace the cotter pin with a new one when removing the castle nut. 10 Pull the hub off of the spindle. The washer and outer bearing should fall loose from the hub. 11 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the inner bearing. 21 Install the dust cap. 22 Install the tire and wheel assembly. Torque the wheel lug nuts to 125 ft-lbs (169.5 Nm). 12 Pack both bearings with clean, fresh grease. 13 Place the large inner bearing into the rear of the hub. 14 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush. Always replace the bearing grease seal when removing the hub. 4 - 36 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Troubleshooting Flow Charts Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie Z-34/22 & Z-34/22N Operator’s Manual. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Read each appropriate flow chart thoroughly. Attempting shortcuts may produce hazardous conditions. Be aware of the following hazards and follow generally accepted safe workshop practices. Repair any machine damage or malfunction before operating the machine. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a flat level surface • Boom in stowed position • Turntable rotated with the boom between the non-steering wheels • Key switch in the OFF position with the key removed • Wheels chocked Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Perform all troubleshooting on a firm level surface. Two persons will be required to safely perform some troubleshooting procedures. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5-1 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing TROUBLESHOOTING FLOW CHARTS General Repair Process About This Section When a malfunction is discovered, the flow charts in this section will help a service professional pinpoint the cause of the problem. To use this section, basic hand tools and certain pieces of test equipment are required—voltmeter, ohmmeter, pressure gauges. The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6, Schematics. Identify symptoms Malfunction discovered Troubleshoot problem still exists Return to service problem solved Inspect and test Perform repair Since various degrees of a particular function loss may occur, selecting the appropriate flow chart may be troublesome. When a function will not operate with the same speed or power as a machine in good working condition, refer to the flow chart which most closely describes the problem. On Z-34/22 models after serial number 1733 and Z-34/22N models after serial number 2227, an LED will flash a fault code to aid in troubleshooting. This LED is mounted on the ground controls panel, located behind the side cover on the ground controls side. 5-2 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Fault Code Chart (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Fault Code Fault Indicator Light is OFF or is ON but not blinking Programmer Diagnostic Display Condition Solution The key switch or Emergency Stop button(s) was cycled on and off faster than 5 seconds OR controller sensed an internal error during start up. Push in the ground control Emergency Stop button to the OFF position and wait for 5 seconds. Pull out the ground control Emergency Stop button to the ON position. If problem persists, replace the motor controller. The motor controller failed self test. Replace the motor controller. The motor controller has an internal short between M- and Bterminals. Test the motor controller. See Repair Section. FIELD OPEN Machine will not drive. Controller fault indicator light on at the platform controls. Motor wiring is loose OR motor is defective OR motor controller has an internal short. Check for loose or open connections at the drive motors and motor controller OR replace the defective drive motor OR test the motor controller. See Repair Section. ARM SENSOR Machine will not drive. Controller fault indicator light on at the platform controls. Defective motor controller. Replace the motor controller. FLD SENSOR Machine will not drive. Controller fault indicator light on at the platform controls. Defective motor controller. Replace the motor controller. COMMUNICATION ERROR 01 Machine will not drive. Controller fault indicator light may or may not be on at the platform controls. Normal operation. 12 HW FAILSAFE 1-2-3 Machine will not drive. Controller fault indicator light on at the platform controls. 13 M- SHORTED Machine will not drive. Controller fault indicator light on at the platform controls. Part No. 36540 Possible Causes Genie Z-34/22 & Genie Z-34/22N 5-3 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing FAULT CODE CHART (Z-34/22 AFTER SERIAL NUMBER 1733 AND Z-34/22N AFTER SERIAL NUMBER 2226) Fault Code 21 31 32 5-4 Programmer Diagnostic Display Condition Possible Causes Solution THROTTLE FAULT 1 Machine will not drive. Controller fault indicator light on at the platform controls. Open in wht/red wire #32 at pin 14 or red/wht wire #29 at pin 16 on the motor controller going from drive joystick to pins 14 and 16 at the motor controller OR pin 14 is internally shorted to power or ground OR the potentiometer on the drive joystick is defective. See Chart 29A THROTTLE FAULT 2 Machine will not drive. Controller fault indicator light on at the platform controls. Pin 14 (wht/red #32) is shorted to power or ground OR the potentiometer on the drive joystick is defective. See Chart 29A CONT DRVR OC Machine will not drive. Controller fault indicator light on at the platform controls. Main contactor (PR1) coil defective OR brake release relay CR5 defective. Replace main contactor PR1 or brake release relay CR5 OR replace the motor controller. Machine will not drive. Controller fault indicator light on at the platform controls. Main contactor (PR1) contacts stuck closed OR grn wire at pin 17 on motor controller shorted to ground OR open in motor armature wiring OR motor controller has an internal short to ground. See Chart 29B MAIN CONT WELDED Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts FAULT CODE CHART (Z-34/22 AFTER SERIAL NUMBER 1733 AND Z-34/22N AFTER SERIAL NUMBER 2226) Fault Code 33 34 Programmer Diagnostic Display Possible Causes Solution PRECHARGE FAULT Machine will not drive. Controller fault indicator light on at the platform controls. External short between B+ terminal on motor controller and ground OR motor controller is defective. Repair short between B+ terminal on motor controller and ground OR replace motor controller. Note: Short can be on any part of circuit connected to the B+ terminal on the motor controller. MISSING CONTACTOR Machine will not drive. Controller fault indicator light on at the platform controls. Motor controller does not detect the main contactor PR1 or brake release relay CR5. See Chart 29C Machine will not drive. Controller fault indicator light on at the platform controls. Main contactor PR1 or brake release relay CR5 did not close OR open in org/red wire to PR1 and/or CR5 OR main contactor and/or brake release relay is defective. See Chart 29C Battery supply voltage to motor controller less than 32V. Completely charge batteries OR check battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller. MAIN CONT DNC 41 Part No. 36540 LOW BATTERY VOLTAGE Condition Machine will not drive. Controller fault indicator light on at the platform controls. Genie Z-34/22 & Genie Z-34/22N 5-5 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing FAULT CODE CHART (Z-34/22 AFTER SERIAL NUMBER 1733 AND Z-34/22N AFTER SERIAL NUMBER 2226) Fault Code 42 43 5-6 Programmer Diagnostic Display OVERVOLTAGE THERMAL CUTBACK Condition Possible Causes Solution Machine will not drive. Controller fault indicator light on at the platform controls. Battery supply voltage to motor controller more than 55V OR machine is being operated with the battery charger plugged in. Be sure the battery charger is disconnected OR check for loose battery cables or poor connections. Machine will not drive. Controller fault indicator light on at the platform controls. Machine being operated outside of temperature range of -13°F to 185°F (-25°C to 85°C) OR machine being driven under excessive load OR motor controller is not being cooled sufficently. Operate machine within specified temperature limits OR check for debris around motor controller preventing proper cooling of the controller OR check for mechanical restrictions causing excessive load on the machine. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 1 All Functions Will Not Operate Be sure key switch is in the appropriate position. Disconnect battery packs and check voltage on each pack. 24V or more Be sure the Emergency Stop buttons are pulled out to the ON position. Connect battery packs and check voltage on the input side of 100A fuse F3. Be sure the circuit breaker and fuses are not tripped or blown. Check voltage on the output side of 100A fuse F3. Be sure the battery packs are properly connected and fully charged. If the Error Indicator light is on at the platform controls, please refer to the specific chart that relates to the error code that is displayed on the ECM. less than Check battery condition 24V and replace bad batteries OR check for short circuits OR check battery cables OR consult Genie Industries Service Department. 0V Repair open in 24V supply cables (positive and negative) from the battery packs. 24V 0V Replace 100A fuse F3 24V Check voltage at the input side of 10A circuit breaker CB1. 0V Repair open in power wire from 100A fuse F3 to PR4 to CB1. 0V Reset or replace circuit breaker CB1 OR consult Genie Industries Service Department. 0V Repair open in red wire from CB1 to the Emergency Stop button. 24V Check voltage at the output side of circuit breaker CB1. 24V Check voltage at the input side of Emergency Stop button P1. 24V Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5-7 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 1 Continued from the previous page. Check voltage at the output side of the Emergency Stop button. 0V Check to see if Emergency Stop button contact is being activated. yes Replace Emergency Stop button contact. yes Replace key switch contact for ground controls. no Replace Emergency Stop button OR refer to Ground Controls Inoperative, Chart 6 OR consult Genie Industries Service Department. 24V Check voltage at the input side of the key switch. 0V Repair open in red wire from Emergency Stop button to key switch. 24V Turn key switch to ground controls and check voltage on output side of ground controls contact of the keyswitch. 0V Check to see if key switch internal cam is activating ground controls contact. no Replace key switch OR refer to Ground Controls Inoperative, Chart 6 OR consult Genie Industries Service Department. 24V Continued on the next page. 5-8 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 1 Continued from the previous page. Turn key switch to platform controls and check voltage on output side of the platform controls contact of the key switch. 0V yes Replace key switch contact for platform controls. no Replace key switch OR refer to Platform Controls Inoperative, Chart 7 OR consult Genie Industries Service Department. 24V Check voltage on the input side of 500A fuse F1. Check to see if the key switch internal cam is activating the platform controls contact. less than Repair open in 48V 48V supply cables (positive and negative) from battery packs. 48V or more Check voltage on the output side of 500A fuse F1. 0V Replace 500A fuse F1. 48V Troubleshoot lift and drive systems separately OR consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5-9 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 2 Lift Pump Motor Will Not Operate Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the on position. Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the primary boom extend/ retract toggle switch TS13 in the RETRACT direction and check voltage at the positive terminal on the lift pump motor. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable switch TS19 to either side and move the primary boom extend/ retract toggle switch TS13 in the RETRACT direction and check voltage at the positive terminal on the lift pump motor. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable switch TS55 to either side and move the primary boom extend/retract toggle switch TS63 in the RETRACT direction and check voltage at the positive terminal on the lift pump motor. 48V Check for continuity in the ground cable circuit from lift pump motor to ground. continuity Repair or replace the lift pump motor. no continuity Replace the ground cable on the lift pump motor OR repair open in the ground cable from the battery packs. 0V Continued on the next page. 5 - 10 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 2 Continued from the previous page. Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at the positive cable on the output side of PR3. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable switch to either side and move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at the positive cable on the output side of PR3. Z-34/22 after serial number 1733 and Z-34/22N after 2226: Hold the function enable switch to either side and move the primary boom extend/retract toggle switch in the RETRACT direction and check voltage at the positive cable on the output side of PR2. 48V Z-34/22 before serial number 153 and Z-34/ 22N before serial number 304: Repair or replace the positive cable from the lift pump motor to PR3. Z-34/22 after serial number 152 and Z-34/22N after 303: Repair or replace the positive cable from the lift pump motor to PR2. 0V Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: Check voltage at the positive cable on the input side of PR3. Z-34/22 after serial number 1733 and Z-34/22N after 2226: Check voltage at the positive cable on the input side of PR2. 48V Continued on the next page. Part No. 36540 0V Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: Replace the 100A fuse F2 OR repair open in the positive cable from the battery packs to the 100A fuse F2 to PR3 OR consult Genie Industries Service Department. Z-34/22 after serial number 1733 and Z-34/22N after 2226: Replace the 100A fuse F2 OR repair open in the positive cable from the battery packs to the 100A fuse F2 to PR2 OR consult Genie Industries Service Department. Genie Z-34/22 & Genie Z-34/22N 5 - 11 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 2 Continued from the previous page. Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage on the grn/wht wire at PR3. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable switch to either side and move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage on the grn/wht wire at PR3. Z-34/22 after serial number 1733 and Z-34/22N after 2226: Hold the function enable switch to either side and move the primary boom extend/retract toggle switch in the RETRACT direction and check voltage on the grn/wht wire at PR2. 24V Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: Check for continuity in the brn ground wire circuit from PR3 to ground. Z-34/22 after serial number 1733 and Z-34/22N after 2226: Check for continuity in the brn ground wire circuit from PR2 to ground. Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: Replace continuity PR3. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Replace PR2. no continuity Z-34/22 before serial number 1734 and Z-34/ 22N before serial number 2227: Repair open in the brn ground wire circuit from PR3 to ground. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Repair open in the brn ground wire circuit from PR2 to ground. 0V Continued on the next page. 5 - 12 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 2 Continued from the previous page. Z-34/22 before serial number 153 and Z-34/ 22N before serial number 304: Move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at terminal #2 on CR2. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable switch to either side and move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at terminal #5 on CR8. Z-34/22 after serial number 1733 and Z-34/ 22N after 2226: Hold the function enable switch to either side and move the primary boom extend/retract toggle switch in the RETRACT direction and check voltage at terminal #87 on CR20. 24V Z-34/22 before serial number 153 and Z-34/ 22N before serial number 304: Repair open in wire circuit from terminal #2 on CR2 to PR3. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Repair open in wire circuit from terminal #5 on CR8 to PR3. Z-34/22 after serial number 1733 and Z-34/ 22N after serial number 2226: Repair open in wire circuit from terminal #87 on CR20 to PR2. 0V Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 13 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 2 Continued from the previous page. Z-34/22 before serial number 153 and Z-34/ 22N before serial number 304: Move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at terminal #6 on CR2. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable switch to either side and move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at terminal #9 on CR8. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable switch to either side and move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at terminal #30 on CR20. 0V Z-34/22 before serial number 153 and Z-34/ 22N before serial number 304: Repair open in grn/wht wire circuit from TB19 to terminal #6 on CR2 OR repair open in function switch wire circuit with diode to TB19 OR repair open in wire circuit from the key switch ground controls contact to the function switch wire circuit OR replace primary boom extend/ retract toggle switch OR contact Genie Industries Service Department. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Repair open in red#20 wire circuit from PR4 to terminal #9 on CR8. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Repair open in red wire circuit from the key switch ground controls contact to the function enable switch to terminal #30 on CR3. 24V Continued on the next page. 5 - 14 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 2 Continued from the previous page. Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Replace CR2. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable switch to either side and move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at terminal #13 on CR8. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable switch to either side and move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at terminal #85 on CR20. 24V Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Repair open in ground wire circuit from terminal #14 on CR8 to ground OR replace CR8 OR replace the relay socket. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Repair open in ground wire circuit with diode from terminal #86 on CR20 to ground OR replace diode OR replace CR20 OR replace the relay socket. 0V Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable switch to either side and move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at terminal #2 on CR2. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable switch to either side and move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at terminal #87A on CR3. 24V Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Repair open in the grn/wht wire circuit from terminal #2 on CR2. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Repair open in the grn/wht wire circuit from terminal #87A on CR3 to terminal #85 on CR20. 0V Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 15 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 2 Continued from the previous page. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable switch to either side and move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at terminal #6 on CR2. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable switch to either side and move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at terminal #30 on CR3. 24V Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Replace CR2. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Replace CR3. 5 - 16 0V Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Repair open in grn/wht wire circuit from TB19 to terminal #6 on CR2 OR repair open in the wire circuit from the key switch ground control contact to the function enable switch to the function switch wire circuit with diode to TB19 OR replace diode OR replace primary boom extend/retract toggle switch OR contact Genie Industries Service Department. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Repair open in grn/wht wire circuit from TB19 to terminal #30 on CR3 OR repair open in the wire circuit from the key switch ground control contact to the function enable switch to the function switch wire circuit with diode to TB19 OR replace diode OR replace primary boom extend/retract toggle switch OR contact Genie Industries Service Department. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 3 Auxiliary Pump Motor Will Not Operate. Be sure all other functions operate normally. Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop motor buttons out to the ON operates position. Lift the red auxiliary pump switch cover and hold the auxiliary toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS17 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS51 in the ON direction. Move any boom function toggle switch and listen for the sound of the auxiliary pump motor operating. Install a 0 to 5000 psi (0 to 345 bar) pressure gauge into the pressure port of the auxiliary pump and hold the auxiliary power toggle switch and move any boom function toggle switch. Note the pressure. Immediately stop. The pump is good. There is 2800 psi possibly not enough battery capacity to operate both the auxiliary pump and function valves. less than 2800 psi Check for a positive connection between the electric motor and the pump by removing the pump from the motor, but leave all the hoses connected. Visually check the coupling connection. good Repair or replace the pump OR consult the Genie Industries Service Department. bad motor does not operate Hold the auxiliary pump toggle switch and move any boom function toggle switch. Check voltage at the red cable on the auxiliary power unit. Replace the auxiliary power unit. 24V no Check continuity in the continuity Replace the ground ground wire circuit from cable from the auxiliary the negative terminal on pump to ground. auxiliary power unit to ground. continuity Replace the auxiliary pump motor. 0V Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 17 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 3 Continued from the previous page. Hold the auxiliary pump toggle switch and move any boom function toggle switch. Check voltage at the grn/wht wire on PR3. 24V no continuity Repair open in the brn ground wire circuit from PR3 to ground. continuity Replace the 500A fuse F1 OR replace the PR3 contacts OR replace PR3. 0V Check voltage at the center terminal on the auxiliary pump toggle switch. Check continuity of the brn ground wire circuit from PR3 to ground. 0V Repair open in the red power supply wire circuit from key switch to the auxiliary pump toggle switch. 24V Hold the auxiliary pump toggle switch and check voltage at TB27. 0V Repair open in the red wire circuit from the auxiliary pump toggle switch to TB27 OR replace toggle switch. 0V Repair open in the red #27 wire from toggle switch to control relay. 24V Hold the auxiliary pump toggle switch and check the voltage red #27 wire on control relay Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: CR2 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: CR3. 24V Continued on the next page. 5 - 18 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 3 Continued from the previous page. no Check continuity of the continuity Repair open in the brn brn ground wire from the ground wire circuit from control relay to ground. control relay to ground. continuity Hold the auxiliary pump toggle switch and move any boom function toggle switch. Check voltage at the control relay output terminal. 0V Replace control relay. 24V Repair open in the red wire from control relay to Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: PR4 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: PR3 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 19 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 4 All Functions Inoperative, Power Unit Starts and Runs Be sure the circuit breaker and fuse are not tripped or blown. Be sure the battery packs are properly connected and fully charged. Check the hydraulic fluid level. low Fill with Dexron equivalent hydraulic fluid. no good Replace the pump coupling. OK Check for a positive connection between the electric motor and the pump by removing the pump from the motor, but leave all hoses connected. Visually check coupling connection. good Test the hydraulic pump. See Repair section. no good Replace the pump. good Consult Genie Industries Service Department. 5 - 20 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 5 All Lift and Steer Functions Inoperative, Drive Function Operational Be sure the battery packs are properly connected and fully charged. Install a 0 to 5000 psi (0 3200 PSI to 345 bar) pressure or more gauge to the test port on the function manifold. Turn key switch to ground controls and pull Emergency Stop buttons out to the ON position, Z-34/22 before serial number 153 and Z-34/ 22N before serial number 304: Move the boom extend/retract toggle switch TS13 in the RETRACT direction and check the hydraulic pressure. Z-34/22 after serial number 152 and Z-34/22N after 303: Hold the function enable toggle switch TS19 to either side and move the boom extend/retract toggle switch TS13 in the RETRACT direction and check the hydraulic pressure. Troubleshoot each function individually OR consult the Genie Industries Service Department. less than 3200 PSI Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 21 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 5 Continued from the previous page. Adjust the relief valve on the function manifold (item AB or BB or BC) all the way in (clockwise), counting the number of turns. Move the boom extend/retract switch in the RETRACT direction. Check the pressure. 3200 PSI or more less than 3200 PSI Z-34/22 before serial number 153 and Z-34/ 22N before serial number 304: Move any boom function toggle switch and manually activate the boom proportional valve (item AU or BU or CH). Does the function operate? Z-34/22 after serial number 152 and Z-34/22N after 303: Hold the function enable toggle switch to either side and move any boom function toggle switch and manually activate the boom proportional valve (item AU or BU or CH). Does the function operate? no Z-34/22 before serial number 153 and Z-34/ 22N before serial number 304: Move TS13 in the RETRACT direction and adjust the relief valve pressure to 3200 PSI OR consult Genie Industries Service Department. Z-34/22 after serial number 152 and Z-34/22N after 303: Hold the function enable toggle switch to either side and move TS13 in the RETRACT direction and adjust the relief valve pressure to 3200 PSI OR consult Genie Industries Service Department. Check function pump (See Repair section). bad Replace the pump. good Replace the boom proportional valve OR replace the differential sensing valve (item AA or BA or CQ) OR function or steer/brake manifolds could have an internal defect. Consult Genie Industries Service Department. yes Continued on the next page. 5 - 22 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 5 Continued from the previous page. no Z-34/22 before serial continuity Repair open in the number 153 and Z-34/ ground wire circuit. 22N before serial number 304: Check for continuity in the ground wire circuit from the proportional valve coil to TB48 to the wht wire at the boom function speed controller. Z-34/22 after serial number 152 and Z-34/22N after 303: Check for continuity in the ground wire circuit from the proportional valve coil to ground. continuity Z-34/22 after serial number 152 and Z-34/22N after 303: Move any boom function toggle switch and check voltage on the wht/red #6 wire on the proportional valve coil. Z-34/22 after serial number 152 and Z-34/22N after 303: Hold the function enable toggle switch to either side and move any boom function toggle switch and check voltage on the wht/red #6 wire on the proportional valve coil. 24V Replace defective coil. 0V Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 23 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 5 Continued from the previous page. Z-34/22 before serial number 153 and Z-34/ 22N before serial number 304: Move any boom function toggle switch and check voltage on the wht/red #6 wire at TB6. Z-34/22 after serial number 152 and Z-34/22N after 303: Hold the function enable toggle switch to either side and move any boom function toggle switch and check voltage on the wht/red #6 wire at TB6. 24V Repair open in the wht/red #6 wire circuit from TB6 to the boom function proportional valve. 0V Repair open in wht/red-3 wire circuit with diode from TB6 to the blk/red wire at the boom function speed controller OR replace diode OR troubleshoot ground and platform control functions separately (refer to charts 6 and 7) OR consult Genie Industries Service Department. 5 - 24 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 6 Ground Controls Inoperative, Platform Controls Operate Normally Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Check voltage at the red wire on the input side of the ground controls contact of the key switch (this wire should originate at the Emergency Stop button). 0V Repair open in the red wire circuit from the Emergency Stop button to the input side of the ground controls contact of the key switch. 24V Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Check voltage at the output side of ground controls contact of the key switch. 0V Check to see if the key switch internal cam is activating the ground controls contact. yes Replace the key switch contact for ground controls. no Replace the key switch. 24V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Hold the secondary boom toggle switch (TS11) in the UP direction and check voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Move the function enable toggle switch to either side and hold the secondary boom toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: (TS11) Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: (TS60) in the UP direction and check voltage at TB6. 0V Check the voltage on the red wire at center terminal of each ground control toggle switch. 0V Repair open in red wire circuit supplying 24V to the center terminal of each ground control toggle switch. 24V Repair open in wht/red wire circuit with diode from TS60 to TB6 OR replace the diode. 24V Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 25 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 6 Continued from the previous page. Move the function enable toggle switch to either side and hold the secondary boom toggle switch in the UP direction. Check voltage at TB19. 0V Repair open in grn/wht wire circuit with diode from TS60 to TB19 OR replace the diode. 24V Consult Genie Industries Service Department. 5 - 26 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 7 Platform Controls Inoperative, Ground Controls Operate Normally (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Check voltage at the red wire on the input side of the platform controls contact of key switch (this wire should originate at the Emergency Stop button). 0V Repair open in the red wire circuit from the Emergency Stop button to the input side of the platform controls contact of the key switch. 20V or more Check voltage at the output side of platform controls contact of the key switch. 0V Check to see if the key switch internal cam is activating the platform controls contact. yes Replace the key switch contact for platform controls. yes Replace the platform Emergency Stop button contact. no Replace the key switch. 20V or more Check voltage at TB22. 0V Repair open in blk #22 wire circuit from key switch to TB22. 20V or more Check voltage at the input side of the platform Emergency Stop button contact. 0V 20V or more Check voltage at the output side of platform Emergency Stop button contact. 0V Repair open in blk-2 wire circuit from TB22 to platform Emergency Stop button OR repair open in ground wire circuit from platform controls to ground. Check to see if the Emergency Stop button is activating the contact. no 20V or more Replace the platform Emergency Stop button. Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 27 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 7 Continued from the previous page. Check the voltage at the input side of the foot switch. 0V Repair open in the wire circuit from the platform Emergency Stop button P2 to foot switch. 0V Replace foot switch contacts OR replace the foot switch. 0V Repair open in the blu/wht-3 wire circuit from foot switch to TB12 0V Repair open in the blk #12 wire circuit from TB12 to LS3. 20V or more Press down foot switch and check voltage on Before serial number 747: the wht wire at the foot switch After serial number 746: the blu/wht wire at the foot switch. 20V or more Press down foot switch and check voltage at TB12. 20V or more Press down foot switch and check voltage at blk #12 wire on LS3. 20V or more Press down foot switch and check voltage at red #16 wire on LS3. 0V Replace LS3. 20V or more Press down foot switch and check voltage at TB16. 0V Repair open in red #16 wire from LS3 to TB16. 20V or more Continued on the next page. 5 - 28 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 7 Continued from the previous page. Press down foot switch and check voltage at terminal "+" on the drive controller. 0V 20V or more Turn the boom function speed controller to 9, press down foot switch and move any boom function toggle switch and check the voltage at the red wire on the boom function speed controller. 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Repair open in the org/red-3 wire circuit from TB16 to terminal "+" on the drive controller. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Repair open in the org/red-3 wire circuit from TB16 to CR5 OR repair or replace CR5 OR repair open in the brn ground wire circuit from CR5 to ground. Repair open in the power supply circuit from each individual boom toggle switch to the boom function speed controller. 20V or more Press down foot switch and move any boom function toggle switch and check the voltage at the blk/red wire on the boom function speed controller. 0V Adjust boom function speed controller OR replace boom function speed controller OR consult Genie Industries Service Department. 20V or more Press down foot switch and move any boom function toggle switch and check voltage at TB6. 0V Repair open in wire circuit with diode from the boom function speed controller to TB6 OR replace diode. 20V or more Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 29 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 7 Continued from the previous page. With the boom function speed controller turned to 9, press down foot switch and move any boom function toggle switch and check voltage at the wht/red wire on the proportional valve coil item AU or BU or CH. 0V Repair open in wht/red wire circuit from proportional valve coil to TB6. 20V or more Disconnect the wire to the proportional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace proportional valve coil. 19 to 20 ohms Z-34/22 before serial number 153 and Z34/22N before serial number 304: Repair open in the blu/wht wire circuit from the proportional valve coil to TB48 to the boom function speed controller OR replace proportional valve (item AU or BU or CH) OR troubleshoot lift and drive functions individually OR consult Genie Industries Service Department. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Repair open in brn ground wire circuit from proportional valve to ground OR replace proportional valve (item AU or BU or CH) OR troubleshoot lift and drive functions individually OR consult Genie Industries Service Department. 5 - 30 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 8 Platform Controls Inoperative, Ground Controls Operate Normally (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Check voltage at the red wire on the input side of the platform controls contact of the key switch (this wire should originate at Emergency Stop button P1). 0V Repair open in red wire circuit from Emergency Stop button to the key switch. 24V Check voltage on the output side of the platform controls contact on the key switch. 0V Check to see if the key switch internal cam is activating the platform controls contact. yes Replace the key switch contact for platform controls. yes Replace the platform Emergency Stop button contact. no Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Replace the keyswitch. 24V Check voltage at TB22. 0V Repair open in blk#22 wire circuit from key switch to TB22. 24V Check voltage at the input side of the platform Emergency Stop button contact. 0V Repair open in blk-2 wire circuit from TB22 to the platform Emergency Stop button OR repair open in brn ground wire circuit from TB52 to the platform. 24V Check voltage at the output side of platform Emergency Stop button contact. 0V Check to see if the Emergency Stop button is activating the contact. no 24V Replace the platform Emergency Stop button. Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 31 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 8 Continued from the previous page. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and check voltage at terminal 6 on the drive controller. 0V Test the foot switch. See Repair Section. good bad Repair open in wht-FS wire circuit from foot switch to the center terminal of TS1 to terminal 6 on the drive controller. Replace the foot switch. 24V Press down the foot switch and check voltage at the center terminal of each function toggle switch. 0V Press down the foot switch and check voltage at the terminal 7 on the drive controller. 24V Repair open in red wire circuit from terminal 6 to terminal 7 on the drive controller to each function toggle switch. 0V Replace the drive controller or consult Genie Industries Service Department. 24V Press down the foot switch and move any boom function toggle switch and check voltage at the red wire on the boom function speed controller. 0V Repair open in power supply circuit to boom function speed controller from each individual boom function toggle switch OR consult Genie Industries Service Department. 24V With the boom function speed controller set to 9, press down the foot switch and move any boom function toggle switch and check voltage at the blk/red wire on boom function speed controller. less than 20V Adjust boom function speed controller (see Repair Section) OR replace boom function speed controller OR consult Genie Industries Service Department. 20V or more Continued on the next page. 5 - 32 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 8 Continued from the previous page. Press down the foot switch and move any boom function toggle switch and check voltage at TB6. 0V Replace the diode on the blk/red wire on boom function speed controller OR repair open in wht/ red-3 wire circuit from boom function speed controller to TB6. 20V or more Press down the foot switch and move any boom function toggle switch and check voltage at the wht/red wire on the proportional valve (item AU or BU or CH). 0V Repair open in wht/red wire from TB6 to the proportional valve. 20V or more Repair open in brn ground wire circuit to the proportional valve OR troubleshoot lift and drive functions individually OR consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 33 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 9 Primary Boom Up Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom toggle switch TS12 in the UP direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the primary boom toggle switch TS12 in the UP direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the primary boom toggle switch TS61 in the UP direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH).. 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom toggle switch in the UP direction and check voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom toggle switch in the up direction and check voltage at TB6. 24V Repair open in the wht/red #6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the brn ground wire circuit from the boom function proportional valve coil to ground. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the primary boom toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS3 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS11 in the UP direction. Check voltage at TB6. 0V Repair open in the blk/ red wire to the wht/red wire to TB6. 15V 24V Continued on page 36. 5 - 34 Continued on the next page. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 9 Continued from the previous page. Press down the foot switch and move the primary boom toggle switch in the UP direction. Check for voltage at the red wire on the boom function speed controller. 0V Repair open in the wire circuit through the boom function toggle switches to the red wire on the boom function speed controller. 24V Press down the foot switch and move the primary boom toggle switch in the UP direction. Check voltage at the blk/red wire on the boom function speed controller. 0V Repair open in the ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in the blk/red to wht/red wire from the boom function speed controller to TB6. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 35 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 9 Continued from page 34. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom toggle switch in the UP direction and check voltage on the red #1 wire on the primary boom up directional valve coil (item AD or BD or CU). Z-34/22 after serial number 153 and Z-34/22N after serial number 304: Hold the function enable toggle switch to either side and move the primary boom toggle switch in the UP direction and check voltage on the red #1 wire on the primary boom up directional valve coil (item AD or BD or CU). 24V 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom toggle switch in the UP direction and check voltage at TB1. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom toggle switch in the UP direction and check voltage at TB1. 24V Repair open in the red #1 wire circuit from TB1 to the primary boom up directional valve coil OR repair open in the brn ground wire circuit to the manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the primary boom toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS3 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS11 in the UP direction. Check voltage at TB1. 0V Repair open in the red-3 wire circuit from primary boom toggle switch to TB1. 24V Troubleshoot the primary boom toggle switch at ground controls OR replace the diode on toggle switch OR repair open in the red #1 wire circuit from toggle switch to TB1 OR replace toggle switch. Continued on the next page. 5 - 36 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 9 Continued from the previous page. Disconnect the red #1 wire to the primary boom up directional valve coil (item AD or BD or CU) and test the resistance of the valve coil. See the Repair Section. 0 or infinite ohms Replace the primary boom up directional valve coil. 23 to 25 ohms Exchange the primary and secondary boom directional valves (items AD and AE or (items BD and BE or items CU and CT). Activate the primary boom UP function. function does not operate function operates Install a 0 to 5000 PSI (0 to 345 bar) pressure gauge at the quick disconnect coupling on the function manifold. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom toggle switch in the up direction and check the pressure. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom toggle switch in the up direction and check the pressure. 3200 PSI Check for mechanical restrictions keeping the primary boom up function from operating OR repair the cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department. less than 3200 PSI Replace the defective directional valve. Part No. 36540 Adjust the system relief valve (item AB or BB or CR) (see Repair Section) OR repair or replace the cylinder or the cylinder counterbalance valve OR the function manifold could have an internal defect. Consult Genie Industries Service Department. Genie Z-34/22 & Genie Z-34/22N 5 - 37 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 10 Primary Boom Down Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom toggle switch TS12 in the DOWN direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the primary boom toggle switch TS12 in the down direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the primary boom toggle switch TS61 in the DOWN direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item CH). 24V Continued on page 40. 5 - 38 0V Hold the function enable toggle switch to either side and move the primary boom toggle switch in the DOWN direction and check the voltage at TB6. 24V Repair open in wht/red #6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit from the boom function proportional valve coil to ground. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the primary boom toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS3 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS11 in the DOWN direction. Check voltage at TB6. 24V Repair open in blk/red wire to wht/red wire to TB6. 0V Press down the foot switch and move the primary boom toggle switch in the DOWN direction. Check voltage at the red wire on the boom function speed controller. 0V Repair open in wire circuit through boom function toggle switches to the red wire on the boom function speed controller. 24V Continued on the next page. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 10 Continued from the previous page. Press down the foot switch and move the primary boom toggle switch in the DOWN direction. Check the voltage at the blk/red wire on the boom function speed controller. 0V Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in blk/red to wht/red wire circuit from the boom function speed controller to TB6. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 39 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 10 Continued from page 38. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom toggle switch in the DOWN direction and check voltage on the red/blk #2 wire at the primary boom down directional valve coil (item I). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226:Hold the function enable toggle switch to either side and move the primary boom toggle switch in the down direction and check voltage on the red/blk #2 wire at the primary boom down directional valve coil (item I). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the primary boom toggle switch in the down direction and check voltage on the red/blk #2 wire at the primary boom down directional valve coil (item AC). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom toggle switch in the DOWN direction and check voltage at TB2. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom toggle switch in the down direction and check voltage at TB2. 24V Repair open in red/blk #2 wire circuit from TB2 to primary boom down directional valve coil OR repair open in brn ground wire circuit to manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the primary boom toggle switch in the DOWN direction. Check voltage at TB2. 0V Repair open in red/blk #2 wire circuit to TB2. 24V Troubleshoot the primary boom toggle switch OR replace diode on toggle switch OR repair open in red/blk #2 wire circuit from toggle switch to TB2 OR replace toggle switch. 24V Continued on the next page. 5 - 40 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 10 Continued from the previous page. Disconnect the red/blk wire to the primary boom down directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace the primary boom down directional valve coil. 23 to 25 ohms function Exchange the primary operates and secondary boom directional valves Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: items D and E Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: items AC and AB. Activate the primary boom DOWN function. Replace defective directional valve. function inoperative Z-34/22 before serial Adjust the system relief number 1734 and valve (see Repair Z-34/22N before serial Section) number 2227: Move the Z-34/22 before serial primary boom toggle number 1734 and switch in the DOWN Z-34/22N before serial number 2227: item B direction and check the less than Z-34/22 after serial pressure. 3200 PSI number 1733 and Z-34/22 after serial Z-34/22N after serial number 1733 and number 2226: item YY Z-34/22N after serial number 2226: Hold the OR repair or replace cylinder or cylinder function enable toggle counterbalance valve switch to either side and OR function manifold move the primary boom could have an internal toggle switch in the defect. Consult Genie down direction and Industries Service check the pressure. Department. 3200 PSI Check for mechanical restrictions keeping the primary boom down function from operating OR repair cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 41 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 11 Secondary Boom Up Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the secondary boom toggle switch TS11 in the UP direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the secondary boom toggle switch TS11 in the UP direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the secondary boom toggle switch TS60 in the UP direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). 24V Continued on page 44. 5 - 42 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the secondary boom toggle switch in the DOWN direction and check voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the secondary boom toggle switch in the DOWN direction and check voltage at TB6. 24V Repair open in wht/red wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit from the boom function proportional valve coil to ground. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the secondary boom toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS2 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS10 in the UP direction. Check voltage at blk/red at boom function speed controller. 24V Repair open in blk/red to wht/red wire circuit to TB6. 0V Continued on the next page. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 11 Continued from the previous page. Press down the foot switch and move the secondary boom toggle switch in the UP direction. Check voltage at the red wire on the boom function speed controller. 0V Repair open in wht/red wire circuit through boom function toggle switches to the red wire on the boom function speed controller. 24V Press down the foot switch and move the secondary boom toggle switch in the UP direction. Check voltage at the blk/red wire on the boom function speed controller. 0V Repair open in grn wire from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in blk/red wire circuit from the boom function speed controller to TB6. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 43 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 11 Continued from page 42. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the secondary boom toggle switch in the UP direction and check voltage on the blu #10 wire on the secondary boom up directional valve coil (item E). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the secondary boom toggle switch in the up direction and check voltage on the blu #10 wire on the secondary boom up directional valve coil (item E). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the secondary boom toggle switch in the up direction and check voltage on the blu #10 wire on the secondary boom up directional valve coil (item AB). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the secondary boom toggle switch in the UP direction and check voltage at TB10. Z-34/22 after serial number 152 and Z34/22N after serial number 303: hold the function enable toggle switch to either side and move the secondary boom toggle switch in the up direction and check voltage at TB10. 24V Repair open in blu #10 wire circuit from TB10 to secondary boom up directional valve coil OR repair open in the ground wire circuit to manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the secondary boom toggle switch in the UP direction and check voltage at TB10. 0V Repair open in blu-3 wire circuit to TB10. 24V Troubleshoot the secondary boom toggle switch OR replace diode on toggle switch OR repair open in blu #10 wire circuit from toggle switch to TB10 OR replace toggle switch. 24V Continued on the next page. 5 - 44 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 11 Continued from the previous page. Disconnect the blu #10 wire to the secondary boom up directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace the secondary boom up directional valve coil. 23 to 25 ohms Exchange the secondary and primary boom directional valves Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: (items D and E) Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: (items AB and AC) Activate the secondary boom UP function. function operates Replace defective directional valve. function inoperative Install a 0 to 5000 PSI (0 Adjust the system relief to 345 bar) pressure valve (see Repair gauge at the quick Section) Z-34/22 before serial disconnect coupling on number 1734 and the function manifold. Z-34/22N before serial Z-34/22 before serial number 2227: item B number 153 and Z34/22N before serial less than Z-34/22 after serial number 304: Move the 3200 PSI number 1733 and Z-34/22N after serial secondary boom toggle number 2226: item YY switch in the UP direction and check the pressure. OR repair or replace cylinder(s) or cylinder(s) Z-34/22 after serial counterbalance valve(s) number 152 and OR function manifold Z34/22N after serial could have an internal number 303: Hold the defect. Consult Genie function enable toggle Industries Service switch to either side and Department. move the secondary boom toggle switch in the UP direction and check the pressure. 3200 PSI Check for mechanical restrictions keeping the secondary boom up function from operating OR repair cylinder(s) or cylinder(s) counterbalance valve(s) OR consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 45 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 12 Secondary Boom Down Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the secondary boom toggle switch TS11 in the DOWN direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the secondary boom toggle switch TS11 in the DOWN direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the secondary boom toggle switch TS60 in the DOWN direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the secondary boom toggle switch in the DOWN direction and check voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the secondary boom toggle switch in the DOWN direction and check voltage at TB6. 24V Repair open in wht/red wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit to boom function proportional valve coil. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the secondary boom toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS2 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS10 in the DOWN direction. Check voltage at blk/red at the boom function speed controller. 24V Repair open in blk/red to wht/red wire circuit to TB6. 0V 24V Continued on page 48. 5 - 46 Continued on the next page. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 12 Continued from the previous page. Press down the foot switch and move the secondary boom toggle switch in the DOWN direction. Check the voltage at the red wire on the boom function speed controller. 0V Repair open in wht/red wire circuit through boom function toggle switches to the red wire on the boom function speed controller. 24V Press down the foot switch and move the secondary boom toggle switch in the DOWN direction. Check voltage at the blk/red wire on the boom function speed controller. 0V Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in blk/red wire from the boom function speed controller to TB6. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 47 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 12 Continued from page 46. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the secondary boom toggle switch in the UP direction and check voltage on the blu #10 wire on the secondary boom up directional valve coil (item AE or BE or CT). Z-34/22 after serial number 153 and Z-34/ 22N after serial number 304: Hold the function enable toggle switch to either side and move the secondary boom toggle switch in the up direction and check voltage on the blu #10 wire on the secondary boom up directional valve coil (item AE or BE or CT). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the secondary boom toggle switch in the DOWN direction and check voltage at TB11. Z-34/22 after serial number 152 and Z34/22N after serial number 303: hold the function enable toggle switch to either side and move the secondary boom toggle switch in the DOWN direction and check voltage at TB11. 24V Repair open in blu #11 wire circuit from TB11 to secondary boom down directional valve coil OR repair open in the ground wire circuit to manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the secondary boom toggle switch in the DOWN direction and check voltage at TB10. 0V Repair open in blu-3 wire circuit to TB10. 24V 24V Troubleshoot the secondary boom toggle switch OR replace diode on toggle switch OR repair open in blu #11 wire circuit from toggle switch to TB11 OR replace toggle switch. Continued on the next page. 5 - 48 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 12 Continued from the previous page. Disconnect the blu #11 wire to the secondary boom down directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace the secondary boom down directional valve coil. 23 to 25 ohms Exchange the secondary and primary boom down directional valves (items AJ and AI or BJ and BI or CU and CT). Activate the secondary boom UP function. function operates Replace defective directional valve. function inoperative Install a 0 to 5000 PSI (0 Adjust the system relief to 345 bar) pressure valve (see Repair gauge at the quick Section) (item AB or BB disconnect coupling on or CR) OR repair or less than replace cylinder(s) or the function manifold. 3200 PSI cylinder(s) Z-34/22 before serial counterbalance valve(s) number 153 and OR function manifold Z34/22N before serial could have an internal number 304: Move the defect. Consult Genie secondary boom toggle Industries Service switch in the DOWN Department. direction and check the pressure. Z-34/22 after serial number 153 and Z-34/22N after serial number 304: Hold the function enable toggle switch to either side and move the secondary boom toggle switch in the DOWN direction and check the pressure. 3200 PSI Check for mechanical restrictions keeping the secondary boom down function from operating OR repair cylinder(s) or cylinder(s) counterbalance valve(s) OR consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 49 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 13 Primary Boom Extend Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom extend/ retract toggle switch TS13 in the EXTEND direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the primary boom extend/ retract toggle switch TS13 in the EXTEND direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the primary boom extend/retract toggle switch TS63 in the EXTEND direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU or CH). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom extend/ retract toggle switch in the EXTEND direction and check voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom extend/retract toggle switch in the EXTEND direction and check voltage at TB6. 24V Repair open in wht/red #6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit to boom function proportional valve coil . 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the primary boom extend/ retract toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS4 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS13 in the EXTEND direction. Check voltage at TP6. 24V Repair open in blk/red wire to TB6. 0V 24V Continued on page 52. 5 - 50 Continued on the next page. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 13 Continued from the previous page. Press down the foot switch and move the primary boom extend/ retract toggle switch in the EXTEND direction. Check voltage at the red wire on the boom function speed controller. 0V Repair open in wire circuit through boom function toggle switches to the red wire on the boom function speed controller. 24V Press down the foot switch and move the primary boom extend/ retract toggle switch in the EXTEND direction. Check voltage at the blk/ red wire on the boom function speed controller. 0V Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in blk/red to wht/red wire from the boom function speed controller to TB6. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 51 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 13 Continued from page 50. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom extend/ retract toggle switch in the EXTEND direction and check voltage on the blk #7 wire primary boom extend directional valve coil (item AT). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the primary boom extend/ retract toggle switch in the EXTEND direction and check voltage on the blk #7 wire primary boom extend directional valve coil (item BT). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the primary boom extend/retract toggle switch in the EXTEND direction and check voltage on the blk #7 wire primary boom extend directional valve coil (item CK). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the secondary boom toggle switch in the EXTEND direction and check voltage at TB7. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom extend/retract toggle switch in the EXTEND direction. Check the voltage at TB7. 24V Repair open in blk #7 wire circuit from TB7 to primary boom extend directional valve coil OR repair open in brn ground wire circuit to manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the primary boom extend/ retract toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS4 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS13 in the EXTEND direction. Check voltage at TB7. 0V Repair open in blk-3 wire circuit to TB7. 24V 24V Troubleshoot the primary boom extend/ retract toggle switch on ground controls OR replace diode on toggle switch OR repair open in blk #7 wire circuit from toggle switch to TB7 OR replace toggle switch. Continued on the next page. 5 - 52 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 13 Continued from the previous page. Disconnect the blk wire to the primary boom extend directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace the primary boom extend directional valve coil . 23 to 25 ohms function Exchange the primary operates boom extend and retract directional valves (items AT and AC or BT and BC or CK and CU). Activate the primary boom EXTEND function. Replace defective directional valve. function inoperative Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 53 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 13 Continued from the previous page. Install a 0 to 5000 PSI (0 Adjust the system relief to 345 bar) pressure valve (see Repair gauge at the quick Section) (item AB or BB disconnect coupling on or CR) OR repair or less than replace cylinder(s) or the function manifold. 3200 PSI cylinder(s) Z-34/22 before serial counterbalance valve(s) number 153 and OR function manifold Z34/22N before serial could have an internal number 304: Move the defect. Consult Genie primary boom extend/ Industries Service retract function toggle Department. switch in the EXTEND direction and check the pressure. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom extend/retract function toggle switch in the EXTEND direction and check the pressure. 3200 PSI Check for mechanical restrictions keeping the primary boom extend function from operating OR repair cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department. 5 - 54 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 14 Primary Boom Retract Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom extend/ retract toggle switch TS13 in the RETRACT direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the primary boom extend/ retract toggle switch TS13 in the RETRACT direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the primary boom extend/retract toggle switch TS63 in the RETRACT direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item CH). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom extend/retract toggle switch in the RETRACT direction and check voltage at TB6. 24V Repair open in wht/red #6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the ground wire circuit to the boom function proportional valve coil . 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the primary boom extend/ retract toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS4 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS13 in the EXTEND direction. Check voltage at TP6. 24V Repair open in blk/red wire circuit from TP6 to to TB6. 0V 24V Continued on page 57. Part No. 36540 Continued on the next page. Genie Z-34/22 & Genie Z-34/22N 5 - 55 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 14 Continued from the previous page. Press down the foot switch and move the primary boom extend/ retract toggle switch in the RETRACT direction. Check voltage at the red wire on the boom function speed controller. 0V Repair open in wht/red wire circuit through boom function toggle switches to the red wire on the boom function speed controller. 24V Press down the foot switch and move the primary boom extend/ retract toggle switch in the RETRACT direction. Check voltage at the blk/ red wire on the boom function speed controller. 0V Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in blk/red wire from the boom function speed controller to TB6. 5 - 56 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 14 Continued from page 55. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom extend/ retract toggle switch in the RETRACT direction and check voltage on the blk/wht #8 wire primary boom retract directional valve coil (item AC). Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom extend/retract toggle switch in the RETRACT direction and check voltage on the blk/wht #8 wire primary boom retract directional valve coil (item AC or BC or CK). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the primary boom toggle switch in the RETRACT direction and check voltage at TB8. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom extend/retract toggle switch in the RETRACT direction. Check the voltage at TB8. 24V Repair open in blk/wht #8 wire circuit from TB8 to primary boom retract directional valve coil OR repair open in brn ground wire circuit to the manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the primary boom extend/ retract toggle switch in the RETRACT direction. Check voltage at TB8. 0V Repair open in blk/wht #8 wire circuit to TB8. 24V 24V Troubleshoot the primary boom extend/ retract toggle switch on ground controls OR replace diode on toggle switch OR repair open in blk/wht #8 wire circuit from toggle switch to TB8 OR replace toggle switch. Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 57 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 14 Continued from the previous page. Disconnect the blk wire to the primary boom extend directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace the primary boom extend directional valve coil. 23 to 25 ohms function Exchange the primary operates boom extend and retract directional valves Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: items AH and AC or BH and BC. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: items CK and CU. Activate the primary boom RETRACT function. Replace defective directional valve. function inoperative Continued on the next page. 5 - 58 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 14 Continued from the previous page. Install a 0 to 5000 PSI Adjust the system relief (0 to 345 bar) pressure valve (see Repair gauge at the quick Section) disconnect coupling on Z-34/22 before serial the function manifold. number 1734 and Z-34/22N before serial Z-34/22 before serial number 2227: number 153 and Z34/22N before serial (item AB or BB) number 304: Move the less than Z-34/22 after serial primary boom extend/ 3200 PSI number 1733 and retract function toggle Z-34/22N after serial switch in the RETRACT number 2226: (item CR) OR repair or direction and check the replace cylinder(s) or pressure. cylinder(s) Z-34/22 after serial counterbalance valve(s) number 152 and OR function manifold Z34/22N after serial could have an internal number 303: Hold the defect. Consult Genie function enable toggle Industries Service switch to either side and Department. move the primary boom extend/retract function toggle switch in the RETRACT direction and check the pressure. 3200 PSI Check for mechanical restrictions keeping the primary boom extend function from operating OR repair cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 59 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 15 Turntable Rotate Left Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled up to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the turntable rotate toggle switch TS10 in the LEFT direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch TS10 in the LEFT direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch TS62 in the LEFT direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item CH). 24V Continued on page 62. 5 - 60 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the turntable rotate toggle switch in the LEFT direction and check the voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the LEFT direction and check the voltage at TB6. 24V Repair open in wht/red #6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the ground wire circuit to the boom function proportional valve coil . 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the turntable rotate toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS1 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS12 in the LEFT direction. Check voltage at TP6. 24V Repair open in blk/red wire circuit from TP6 to to TB6. 0V Continued on the next page. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 15 Continued from the previous page. Press down the foot switch and move the turntable rotate toggle switch in the LEFT direction. Check the voltage at the red wire on the boom function speed controller. 0V Repair open in wht/red wire circuit through boom function toggle switches to the red wire on the boom function speed controller. 24V Press down the foot switch and move the turntable rotate function toggle switch in the LEFT direction. Check the voltage at the blk/red wire on the boom function speed controller. 0V Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in blk/red wire from the boom function speed controller to TB6. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 61 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 15 Continued from page 60. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the turntable rotate toggle switch in the LEFT direction and check voltage on the wht #4 wire on the turntable rotate directional valve coil (item AF). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the LEFT direction and check voltage on the wht #4 wire on the turntable rotate directional valve coil (item AF or BF). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the LEFT direction and check voltage on the wht #4 wire on the turntable rotate directional valve coil (item CD). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the turntable rotate toggle switch in the LEFT direction and check voltage at TB4. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the LEFT direction and check voltage at TB4. 24V Repair open in wht/blk #4 wire circuit from TB4 to turntable rotate left directional valve coil OR repair open in brn ground wire circuit to manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the turntable rotate toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS4 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS13 in the LEFT direction. Check voltage at TB5. 0V Repair open in wht-3 wire circuit to TB5. 24V 24V Troubleshoot the turntable rotate toggle switch OR replace diode on toggle switch OR repair open in wht-3 wire circuit from toggle switch to TB4 OR replace toggle switch. Continued on the next page. 5 - 62 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 15 Continued from the previous page. Disconnect the wire to the turntable rotate left directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace the turntable rotate left directional valve coil. 23 to 25 ohms Exchange the turntable rotate and secondary boom directional valves Z-34/22 before serial number 674 and Z-34/22N before serial number 935: item AF and AK. Z-34/22 from serial number 674 to 1733 and Z-34/22N from serial number 935 to 2226: item BF and BK. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: item CX and CJ. Activate the turntable rotate LEFT function. function operates Replace defective directional valve. function inoperative Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 63 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 15 Continued from the previous page. Install a 0 to 5000 PSI (0 to 345 bar) pressure gauge at the quick disconnect coupling on the function manifold. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the turntable rotate toggle switch in the LEFT direction and check the pressure. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the LEFT direction and check the pressure. 3200 PSI Check for mechanical restrictions keeping the turntable rotate left function from operating OR repair or replace the turntable rotation motor OR consult Genie Industries Service Department. less than 3200 PSI Adjust the system relief valve (see Repair Section) (item AB or BB or CR) OR repair or replace the turntable rotation motor OR function manifold could have an internal defect. Consult Genie Industries Service Department. 5 - 64 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 16 Turntable Rotate Right Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled up to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the turntable rotate toggle switch TS10 in the RIGHT direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch TS10 in the RIGHT direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch TS62 in the RIGHT direction and check voltage on the wht/red #6 wire at the boom function proportional valve coil (item CH). 24V Continued on page 67. Part No. 36540 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the turntable rotate toggle switch in the RIGHT direction and check the voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check the voltage at TB6. 24V Repair open in wht/red #6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the ground wire circuit to the boom function proportional valve coil . 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the turntable rotate toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS1 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS12 in the RIGHT direction. Check voltage at TP6. 24V Repair open in blk/red wire circuit from TP6 to to TB6. 0V Continued on the next page. Genie Z-34/22 & Genie Z-34/22N 5 - 65 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 16 Continued from the previous page. Press down the foot switch and move the turntable rotate toggle switch in the RIGHT direction. Check the voltage at the red wire on the boom function speed controller. 0V Repair open in red/wht wire circuit through boom function toggle switches to the red wire on the boom function speed controller. 24V Press down the foot switch and move the turntable rotate function toggle switch in the RIGHT direction. Check the voltage at the blk/red wire on the boom function speed controller. 0V Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in blk/red wire from the boom function speed controller to TB6. 5 - 66 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 16 Continued from page 65. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the turntable rotate toggle switch in the RIGHT direction and check voltage on the wht #5 wire on the turntable rotate directional valve coil (item AK). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check voltage on the wht #5 wire on the turntable rotate directional valve coil (item AK or BK). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check voltage on the wht #5 wire on the turntable rotate directional valve coil (item CX). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the turntable rotate toggle switch in the RIGHT direction and check voltage at TB5. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check voltage at TB5. 24V Repair open in wht/blk #5 wire circuit from TB5 to turntable rotate right directional valve coil OR repair open in brn ground wire circuit to the manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the turntable rotate toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS1 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS12 in the RIGHT direction. Check voltage at TB5. 0V Repair open in wht/blk-3 wire circuit to TB5. 24V 24V Troubleshoot the turntable rotate toggle switch OR replace diode on toggle switch OR repair open in wht #5 wire circuit from toggle switch to TB5 OR replace toggle switch. Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 67 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 16 Continued from the previous page. Disconnect the wire to the turntable rotate right directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace the turntable rotate right directional valve coil. 23 to 25 ohms Exchange the turntable rotate and secondary boom directional valves (items AE and AK or items BE and BK or items CX and CJ). Activate the turntable rotate RIGHT function. function operates Replace defective directional valve. function inoperative Install a 0 to 5000 PSI (0 to 345 bar) pressure gauge at the quick disconnect coupling on the function manifold. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the turntable rotate toggle switch in the RIGHT direction and check the pressure. Z-34/22 after serial number 153 and Z-34/22N after serial number 304: Hold the function enable toggle switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check the pressure. 3200 PSI Check for mechanical restrictions keeping the turntable rotate left function from operating OR repair or replace the turntable rotation motor OR consult Genie Industries Service Department. less than 3200 PSI Adjust the system relief valve (see Repair Section) (item AB or BB or CR) OR repair or replace the turntable rotation motor OR function manifold could have an internal defect. Consult Genie Industries Service Department. 5 - 68 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 17 All Platform Level Functions Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Remove both hydraulic hoses from the function manifold (ports C1 and C2). Plug the hoses and cap the manifold fittings. Move the primary boom toggle switch TS12 in the UP direction. Does the platform level? Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Remove both hydraulic hoses from the function manifold (ports C1 and C2). Plug the hoses and cap the manifold fittings. Hold the function enable switch to either side and move the primary boom toggle switch TS12 in the UP direction. Does the platform level? Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Remove both hydraulic hoses from the function manifold (ports L1 and L2). Plug the hoses and cap the manifold fittings. Hold the function enable switch to either side and move the primary boom toggle switch TS61 in the UP direction. Does the platform level? yes Replace the counterbalance valves in the function manifold (items AN and AO or items BN and BO or items CB and CC). no Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 69 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 17 Continued from the previous page. less than Z-34/22 before serial Install a 0 to 5000 psi 2000 PSI Repair or replace the number 153 and (0 to 345 bar) pressure master cylinder. Z34/22N before serial gauge into the barrelnumber 304: Plumb a 0 end hydraulic hose (hose connected to to 5000 psi (0 to 345 bar) pressure gauge into less than port C2 OR L2) from the master cylinder rod-end 2000 PSI master cylinder and raise the primary boom hydraulic hose (hose one inch (2.5 cm) at a connected to port C1) time. Continually using a tee fitting. Move monitor the pressure the primary boom toggle gauge while raising the switch in the UP direction primary boom. Do not and check the pressure. allow the pressure to Z-34/22 after serial exceed 2500 PSI. number 152 and Z34/22N after serial number 303: Plumb a 0 2000 PSI or more to 5000 psi (0 to 345 bar) pressure gauge into master cylinder rod-end Repair or replace the hydraulic hose slave cylinder. Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: (hose connected to port C1) Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: (hose connected to port L1) using a tee fitting. Hold the function enable switch to either side and move the primary boom toggle switch in the UP direction and check the pressure. 2000 PSI Check for mechanical restrictions keeping the platform level function from operating OR replace the slave cylinder counterbalance valves. 5 - 70 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 18 Platform Level Up Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the on position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform level toggle switch TS14 in the UP direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the platform level toggle switch TS14 in the UP direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the platform level toggle switch TS59 in the UP direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item CH). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform level toggle switch in the UP direction and check the voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the platform level toggle switch in the UP direction and check the voltage at TB6. 24V Repair open in wht/red #6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the ground wire circuit to the boom function proportional valve coil . 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the platform level toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS5 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS9 in the UP direction. Check voltage at TP6. 0V Repair open in wht/red wire circuit from TP6 to to TB6. 24V 24V Continued on page 73. Part No. 36540 Continued on the next page. Genie Z-34/22 & Genie Z-34/22N 5 - 71 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 18 Continued from the previous page. Press down the foot switch and move the platform level toggle switch in the UP direction. Check the voltage at the red wire on the boom function speed controller. 0V Repair open in grn/wht wire circuit through boom function toggle switches to the red wire on the boom function speed controller. 24V Press down the foot switch and move the platform level toggle switch in the UP direction. Check the voltage at the blk/red wire on the boom function speed controller. 0V Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in blk/red wire from the boom function speed controller to TB6. 5 - 72 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 18 Continued from page 71. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move platform level toggle switch in the UP direction and check voltage on the org #14 wire on the platform level up directional valve coil (item AG). Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move platform level toggle switch in the UP direction and check voltage on the org #14 wire on the platform level up directional valve coil (item AG or BG or CA). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform level toggle switch in the UP direction and check voltage at TB14. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the platform level toggle switch in the UP direction and check voltage at TB14. 24V Repair open in org #14 wire circuit from TB14 to platform level up directional valve coil OR repair open in brn ground wire circuit to the manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the platform level toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS5 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS9 in the UP direction. Check voltage at TB14. 24V 0V Repair open in power supply wiring to platform level toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: (TS14) Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: (TS59) on ground controls OR Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: (TS5) Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: (TS9) on the platform controls. 24V Repair open in org-3 wire to TB14. Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 73 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 18 Continued from the previous page. Disconnect the org wire from the platform level up directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace platform level up directional valve coil. 23 to 25 ohms Exchange the platform level and secondary boom directional valves (items AG, AL, and AE, AJ or BG, BL and BE, BJ or CA and CT). Activate the platform level UP function. function operates Replace defective directional valve. function inoperative Exchange the platform level counterbalance valves (items AN and AO or items BN and BO or items CC and CB). Activate the platform level UP function. function operates Replace defective counterbalance valve. function inoperative Continued on the next page. 5 - 74 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 18 Continued from the previous page. Install a 0 to 3000 psi (0 to 345 bar) pressure gauge at the quick disconnect coupling on 2800 psi the boom function manifold. Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: Move the platform level up toggle switch and check the pressure. Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the platform level up toggle switch and check the pressure. Check for mechanical restrictions keeping platform level up function from moving OR replace slave cylinder counterbalance valves OR consult Genie Industries Service Department. less than 2800 psi Test master cylinder OR repair or replace slave cylinder or slave cylinder counterbalance valves OR boom function manifold could have an internal defect. Consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 75 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 19 Platform Level Down Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the on position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform level toggle switch TS14 in the DOWN direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the platform level toggle switch TS14 in the DOWN direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the platform level toggle switch TS59 in the DOWN direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item CH). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform level toggle switch in the DOWN direction and check the voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the platform level toggle switch in the DOWN direction and check the voltage at TB6. 24V Repair open in wht/red #6 wire circuit from TB6 to the boom function proportional valve coil OR repair open in the ground wire circuit to the boom function proportional valve coil . 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the platform level toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS5 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS9 in the DOWN direction. Check voltage at TP6. 0V Repair open in wht/red wire circuit from TP6 to to TB6. 24V 24V Continued on page 78. 5 - 76 Continued on the next page. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 19 Continued from the previous page. Press down the foot switch and move the platform level toggle switch in the DOWN direction. Check the voltage at the red wire on the boom function speed controller. 0V Repair open in grn/wht wire circuit through boom function toggle switches to the red wire on the boom function speed controller. 24V Press down the foot switch and move the platform level toggle switch in the DOWN direction. Check the voltage at the blk/red wire on the boom function speed controller. 0V Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in blk/red wire from the boom function speed controller to TB6. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 77 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 19 Continued from page 76. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move platform level toggle switch in the DOWN direction and check voltage on the org #15 wire on the platform level up directional valve coil (item AL). Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move platform level toggle switch in the DOWN direction and check voltage on the org #15 wire on the platform level up directional valve coil (item AL or BL or CB). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform level toggle switch in the DOWN direction and check voltage at TB15. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the platform level toggle switch in the DOWN direction and check voltage at TB15. 24V Repair open in org/blk #15 wire circuit from TB15 to platform level down directional valve coil OR repair open in brn ground wire circuit to the manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch, and move the platform level toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS5 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS9 in the DOWN direction. Check voltage at TB15. 24V Repair open in org/blk #15 wire to TB15. 24V 0V Repair open in power supply wiring to platform level toggle switch at ground controls OR platform controls. Continued on the next page. 5 - 78 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 19 Continued from the previous page. Disconnect the org/blk wire from the platform level down directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace platform level down directional valve coil. 23 to 25 ohms Exchange the platform level and turntable rotate directional valves (items AL and AJ or items BL and BJ or items CA and CT). Activate the platform level DOWN function. function operates Replace defective directional valve. function inoperative Exchange the platform level counterbalance valves (items AN and AO or items BN and BO or items CB adn CC). Activate the platform level DOWN function. function operates Replace defective counterbalance valve. function inoperative Install a 0 to 5000 PSI (345 bar) pressure gauge at the quick disconnect coupling on the function manifold. Activate the platform level down function and check the pressure. 3200 PSI Check for mechanical restrictions keeping the platform level down function from operating OR repair or replace the slave cylinder or slave cylinder counterbalance valves OR consult Genie Industries Service Department. less than 3200 PSI Test the master cylinder (refer to Chart #16) OR repair or replace the slave cylinder counterbalance valves OR function manifold could have an internal defect. Consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 79 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 20 Platform Rotate Left Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled up to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform rotate toggle switch TS15 in the LEFT direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the platform rotate toggle switch TS15 in the LEFT direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the platform rotate toggle switch TS57 in the LEFT direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item CH). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform rotate toggle switch in the LEFT direction and check the voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the platfrom rotate toggle switch in the LEFT direction and check the voltage at TB6. 24V Repair open in wht/red #6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit to boom function proportional valve coil. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the platform rotate toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS6 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS7 in the LEFT direction. Check voltage at TP6. 0V Repair open in wht/red wire circuit from TP6 to to TB6. 24V 24V Continued on page 82. 5 - 80 Continued on the next page. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 20 Continued from the previous page. Press down the foot switch and move the platform level toggle switch in the LEFT direction. Check the voltage at the red wire on the boom function speed controller. 0V Repair open in grn/wht wire circuit through boom function toggle switches to the red wire on the boom function speed controller. 24V Press down the foot switch and move the platform rotate toggle switch in the LEFT direction. Check voltage at the blk/red wire on the boom function speed controller. 0V Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in blk/red wire from the boom function speed controller to TB6. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 81 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 20 Continued from page 80. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move platform rotate toggle switch in the LEFT direction and check voltage on the grn wire on the platform rotate left directional valve coil (item D). Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the platform rotate toggle switch in the LEFT direction and check voltage on the grn wire on the platform rotate left directional valve coil (item D). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform rotate toggle switch in the LEFT direction and check voltage at TB17. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the platform rotate toggle switch in the LEFT direction and check voltage at TB17. 24V Repair open in org wire circuit from TB17 to platform rotate left directional valve coil OR repair open in brn ground wire circuit to the manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the platform rotate toggle switch in the LEFT direction. Check voltage at platform rotate left directional valve coil. 24V Repair open in the ground wire circuit on the platform rotate left directional coil. 0V 24V Repair open in power supply wiring to platform rotate toggle switch on ground controls or on the platform controls. Continued on the next page. 5 - 82 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 20 Continued from the previous page. Disconnect the org wire from the platform rotate left directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace platform rotate left directional valve coil . 23 to 25 ohms Exchange the platform rotate left and jib boom up directional valves (items D and A). Activate the platform rotate LEFT function. function operates Replace defective directional valve. function inoperative Install a 0 to 3000 psi (0 to 207 bar) pressure gauge at the quick disconnect coupling on the boom function manifold and activate the platform rotate LEFT function. Repair hydraulic rotation less than motor OR platform 2800 psi rotate/jib function manifold could have an internal defect. Consult Genie Industries Service Department. 2800 psi Check for mechanial restrictions keeping platform rotate LEFT function from moving OR the Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: 0.030" orifice (item W) Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: 0.025" orifice (item W) could be plugged OR repair hydraulic rotation motor OR consult Genie Industried Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 83 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 21 Platform Rotate Right Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform rotate toggle switch TS15 in the RIGHT direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the platform rotate toggle switch TS15 in the RIGHT direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the platform rotate toggle switch TS57 in the RIGHT direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item CH). 24V Continued on page 86. 5 - 84 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform rotate toggle switch in the RIGHT direction and check the voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the platfrom rotate toggle switch in the RIGHT direction and check the voltage at TB6. 24V Repair open in wht/red #6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit to boom function proportional valve coil. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the platform rotate toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS6 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS7 in the RIGHT direction. Check voltage at TP6. 0V Repair open in wht/red wire circuit from TP6 to to TB6. 24V Continued on the next page. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 21 Continued from the previous page. Press down the foot switch and move the platform rotate toggle switch in the RIGHT direction. Check voltage at the red wire on the boom function speed controller. 0V Repair open in grn/wht wire circuit through boom function toggle switches to the red wire on the boom function speed controller. 24V Press down the foot switch and move the platform rotate toggle switch in the RIGHT direction. Check voltage at the blk/red wire on the boom function speed controller. 0V Repair open in ground wire circuit from the boom function speed controller to ground OR replace the boom function speed controller. 24V Repair open in blk/red wire from the boom function speed controller to TB6. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 85 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 21 Continued from page 84. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move platform rotate toggle switch in the RIGHT direction and check voltage on the yel wire on the platform rotate right directional valve coil (item B). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move platform rotate toggle switch in the RIGHT direction and check voltage on the yel wire on the platform rotate right directional valve coil (item B). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move platform rotate toggle switch in the RIGHT direction and check voltage on the blu wire on the platform rotate right directional valve coil (item B). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the platform rotate toggle switch in the RIGHT direction and check voltage at TB18. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the platform rotate toggle switch in the RIGHT direction and check voltage at TB18. 24V Repair open in wire circuit from TB18 to platform rotate right directional valve coil OR repair open in brn ground wire circuit to the manifold. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the platform rotate toggle switch in the RIGHT direction. Check voltage at the platform rotate right directional valve coil. 24V Repair open in the ground wire circuit on the platform rotate right directional coil. 0V Repair open in power supply wiring to platform rotate toggle switch on ground controls OR on the platform controls. 24V Continued on the next page. 5 - 86 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 21 Continued from the previous page. Disconnect the wires from the platform rotate right directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace platform rotate right directional valve coil. 23 to 25 ohms function Exchange the platform rotate right and jib boom operates up directional valves (item B and A). Activate the platform rotate RIGHT function. Replace defective directional valve. function inoperative Install a 0 to 3000 psi (0 to 207 bar) pressure gauge at the quick disconnect coupling on the boom function manifold and activate the platform rotate right function. Repair hydraulic rotation less than motor OR platform 3200 psi rotate/jib function manifold could have an internal defect. Consult Genie Industries Service Department. 3200 psi Check for mechanial restrictions keeping platform rotate right function from moving OR the Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: 0.030" orifice (item C) Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: 0.025 orifice (item C) could be plugged OR repair hydraulic rotation motor OR consult Genie Industried Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 87 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 22 Jib Boom Up Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the jib toggle switch TS16 in the UP direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU). Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Hold the function enable toggle switch to either side and move the jib toggle switch TS16 in the UP direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU). Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the jib toggle switch TS58 in the UP direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item CH). 20V or more 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the jib toggle switch in the UP direction and check voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the jib toggle switch in the UP direction and check voltage at TB6. 20V or more Repair open in wht/red #6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit to boom function proportional valve coil. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With boom function speed controller turned to 9, press down the foot switch and move the jib toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS7 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS8 in the UP direction. Check voltage at TB6. 0V Troubleshoot jib function toggle switches on ground and platform controls OR repair open in wht/red #6 wire circuit from ground controls toggle switch to TB6 and from platform controls toggle switch to red wire on boom function speed controller OR consult Genie Industries Service Department. 20V or more Troubleshoot jib function toggle switch on ground controls OR repair open in wht/red #6 wire circuit from toggle switch to TB6 OR consult Genie Industries Service Department. If voltage to TB6 from toggle switch at ground control and toggle switch at platform control has been restored and jib up function is still inoperative, continue trouble shooting from beginning of chart. Continued on the next page. 5 - 88 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 22 Continued from the previous page. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move jib toggle switch in the UP direction and check voltage on the blk wire on the jib up directional valve coil (item A). Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side and move jib toggle switch in the UP direction and check voltage on the yel wire on the jib up directional valve coil (item A). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the jib toggle switch in the UP direction and check voltage at TB43. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the jib toggle switch in the UP direction and check voltage at TB43. 20V or more Repair open in the grn-1 to blk-jib wire circuit from TB43 to the jib up directional valve coil OR repair open in the ground wire circuit to valve coil. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the jib toggle switch in the UP direction. Check voltage on the blk-jib wire at jib up directional valve coil. 0V Troubleshoot jib toggle switches on ground and platform controls OR replace diodes on toggle switches OR repair open in grn-1 to blk-jib wire circuit from toggle switches to jib up directional valve coil OR consult Genie Industries Service Department. 20V or more 20V or more Troubleshoot jib function toggle switch on ground controls OR replace diode on toggle switch OR repair open in grn-1 to blk-jib wire circuit from toggle switch to boom function directional valve coil OR consult Genie Industries Service Department. If voltage to boom function directional valve coil from ground toggle switch and platform toggle switch has been restored and jib up function is still inoperative, continue trouble shooting from beginning of chart. Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 89 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 22 Continued from the previous page. Disconnect the wires from the jib up directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace jib up directional valve coil. 23 to 25 ohms Exchange the jib up and function operates jib down directional valves (item A and E). Activate the jib up function. Replace defective directional valve. function inoperative Install a 0 to 3000 PSI (0 to 207 bar) pressure gauge at the quick disconnect coupling on the boom function manifold. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the jib toggle switch in the UP direction. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the jib toggle switch in the UP direction. 2800 PSI Check for mechanical restrictions keeping jib up function from moving OR repair or replace jib cylinder OR replace jib cylinder counterbalance valves OR consult Genie Industries Service Department. less than 2800 PSI Repair or replace jib cylinder OR replace jib cylinder counterbalance valves OR platform rotate/jib function manifold could have an internal defect. Consult Genie Industries Service Department. 5 - 90 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 23 Jib Boom Down Function Inoperative Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the jib toggle switch TS16 in the DOWN direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU). Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the jib toggle switch TS16 in the DOWN direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item AU or BU). Z-34/22 after serial number 1733 and Z34/22N after serial number 2226: Hold the function enable toggle switch to either side and move the jib toggle switch TS58 in the DOWN direction and check the voltage on the wht/red #6 wire at the boom function proportional valve coil (item CH). 20V or more 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the jib toggle switch in the DOWN direction and check the voltage at TB6. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the jib toggle switch in the DOWN direction and check the voltage at TB6. 20V or more Repair open in wht/red #6 wire circuit from TB6 to boom function proportional valve coil OR repair open in brn ground wire circuit to boom function proportional valve coil. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch and move the jib toggle switch Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: TS7 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: TS8 in the DOWN direction. Check voltage at TB6. 0V Troubleshoot jib function toggle switches on ground and platform controls OR repair open in wht/red #6 wire circuit from ground controls toggle switch to TB6 and from platform controls toggle switch to red wire on boom rotary speed controller OR consult Genie Industries Service Department. 20V or more Troubleshoot jib function toggle switch on ground controls OR repair open in wht/red #6 wire circuit from toggle switch to TB6 OR consult Genie Industries Service Department. If voltage to TB6 from toggle switch at ground control and toggle switch at platform control has been restored and jib down function is still inoperative, continue trouble shooting from beginning of chart. Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 91 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 23 Continued from the previous page. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move platform jib toggle switch in the DOWN direction and check voltage on the wht wire on the jib down directional valve coil (item E). Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move jib toggle switch in the DOWN direction and check voltage on the wht wire on the jib down directional valve coil (item E). 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the jib toggle switch in the DOWN direction and check voltage at TB44. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the jib toggle switch in the DOWN direction and check voltage at TB44. 20V or more Repair open in grn/blk-1 to wht-jib wire circuit from TB44 to jib down directional valve coil OR repair open in ground wire circuit to valve coil. 0V Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the boom function speed controller turned to 9, press down the foot switch. Hold the jib function toggle switch in the DOWN direction and check voltage on wht-jib wire on jib down directional valve coil. 0V Troubleshoot jib function toggle switches on ground and platform controls OR replace diodes on toggle switches OR repair open in grn/blk-1 to wht-jib wire circuit from toggle switches to jib down directional valve coil OR consult Genie Industries Service Department. 20V or more 20V or more Troubleshoot jib function toggle switch on ground controls OR replace diode on toggle switch OR repair open in grn-1 to sht-jib wire circuit from toggle switch to jib down directional valve coil OR consult Genie Industries Service Department. If voltage to jib down directional valve coil from ground toggle switch and platform toggle switch has been restored and jib up function is still inoperative, continue trouble shooting from beginning of chart. Continued on the next page. 5 - 92 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 23 Continued from the previous page. Disconnect the wires from the jib down directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace jib down directional valve coil. 23 to 25 ohms Exchange the jib up and function operates jib down directional valves (item A and E). Activate the jib down function. Replace defective directional valve. function inoperative Install a 0 to 3000 PSI (0 to 207 bar) pressure gauge at the quick disconnect coupling on the boom function manifold. Z-34/22 before serial number 153 and Z34/22N before serial number 304: Move the jib toggle switch in the DOWN direction. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Hold the function enable toggle switch to either side and move the jib toggle switch in the DOWN direction. 3200 PSI Check for mechanical restrictions keeping jib down function from moving OR repair or replace jib cylinder OR replace jib cylinder counterbalance valves OR consult Genie Industries Service Department. less than 3200 PSI Repair or replace jib cylinder OR replace jib cylinder counterbalance valves OR platform rotate/jib function manifold could have an internal defect. Consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 93 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 24 Steer Left Function Inoperative (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Be sure all other functions operate normally. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and press the steer rocker switch in the LEFT direction and check voltage on TB36. 0V 0V Repair or replace the steer microswitch OR consult Genie Industries Service Department. 20V or more Repair open in blu-1 wire circuit from drive controller to TB36. 20V or more Press down the foot switch and press the steer rocker switch in the LEFT direction and check voltage on TB19. Press down the foot switch and press the steer rocker switch in the LEFT direction and check voltage at the drive contoller terminal with the blu-1 wire attached. 0V Repair open in the wire circuit with diode from TB36 to TB19. 20V or more Press down the foot switch and press the steer rocker switch in the LEFT direction and check voltage on blu #36 wire at the steer left directional valve coil (item I) on the steer/brake manifold. 0V 20V or more Disconnect the wires from the steer left directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace steer left directional valve coil. 20 to 25 ohms Install a 0 to 3000 PSI (0 to 207 bar) pressure gauge at the quick disconnect coupling on the boom function manifold. Press down the foot switch and press the steer rocker switch in the LEFT direction and check the pressure. 2800 psi Check for mechanical restrictions keeping steer left function from moving OR the 0.085" orifice (item O) is plugged OR repair or replace steer cylinder OR consult Genie Industries Service Department. less than 2800 psi Repair or replace steer cylinder OR the steer/brake function manifold could have an internal defect OR consult Genie Industries Service Department. Repair open in blu #36 wire circuit from TB36 to the steer left directional valve coil. 5 - 94 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 25 Steer Left Function Inoperative (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Be sure all other functions operate normally. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and press the steer rocker switch on the drive controller in the LEFT direction. Check voltage at TB36. 0V 0V Repair or replace the steer microswitch on the the drive controller OR consult Genie Industries Service Department. 20V or more Repair open in blu-1 wire circuit from drive controller terminal "9" to TB36. 20V or more Press down the foot switch and press the steer rocker switch in the LEFT direction. Check voltage at TB19. Press down the foot switch and press the steer rocker switch in the LEFT direction. Check voltage at terminal "9" on the drive controller. 0V Repair open in grn/wht #19 wire circuit with diode from TB36 to TB19 OR replace the diode. 20V or more Press down the foot switch and press the steer rocker switch in the LEFT direction. Check voltage on the blu #36 wire at the steer left directional valve coil (item CJ). 0V Repair open in blu #36 wire circuit from TB36 to the steer left directional valve coil OR repair open in brn ground wire circuit to the function manifold. 20V or more Disconnect the blu #36 wire to the steer left directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace steer left directional valve coil. 23 to 25 ohms Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 95 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 25 Continued from the previous page. function Exchange the steer operates directional valve (item CJ) with the turntable rotate directional valve (item CX). Test the steer left function. Replace defective directional valve. function inoperative Install a 0 to 5000 PSI (0 to 345 bar) pressure gauge at the quick disconnect coupling on the function manifold. Press down the foot switch and press the steer rocker switch in the LEFT direction and check the pressure. 3200 PSI Check for mechanical restrictions keeping the steer right function from operating OR the 0.045" orifice (item CN) may be plugged OR repair or replace the steer cylinder OR consult Genie Industries Service Department. less than 3200 psi Repair or replace the steer cylinder OR the function manifold may have an internal defect. Consult Genie Industries Service Department. 5 - 96 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 26 Steer Right Function Inoperative (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled up to the ON position. Be sure the battery packs are properly connected and fully charged. Be sure all other functions operate normally. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and press the steer rocker switch in the RIGHT direction and check voltage on TB37. 0V 0V Repair or replace the steer microswitch OR consult Genie Industries Service Department. 20V or more Repair open in blu/blk-1 wire circuit from the drive controller to TB36. 20V or more Press down the foot switch and press the steer rocker switch in the RIGHT direction and check voltage on TB19. Press down the foot switch and press the steer rocker switch in the RIGHT direction and check voltage at the drive controller terminal where the blu/blk-1 wire is attached. 0V Repair open in wire circuit with diode from TB37 to TB19. 20V or more Press down the foot switch and press the steer rocker switch in the RIGHT direction and check voltage on blu/blk #37 wire at the steer right directional valve coil (item I) on the steer/ brake manifold. 0V 20V or more Disconnect the wires from the steer right directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace steer right directional valve coil. 20 to 25 ohms Install a 0 to 3000 PSI (0 to 207 bar) pressure gauge at the quick disconnect coupling on the boom function manifold. Press down the foot switch and press the steer rocker switch in the RIGHT direction and check the pressure. 3200 PSI Check for mechanical restrictions keeping steer right function from moving OR the 0.085" orifice (item O) is plugged OR repair or replace steer cylinder OR consult Genie Industries Service Department. less than 3200 PSI Repair or replace steer cylinder OR the steer/ brake function manifold could have an internal defect OR consult Genie Industries Service Department. Repair open in blu/blk #37 wire circuit from TB37 to the steer right directional valve coil. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 97 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 27 Steer Right Function Inoperative (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Be sure all other functions operate normally. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and press the steer rocker switch on the drive controller in the RIGHT direction. Check voltage at TB37. 0V 20V or more Repair open in blu/blk -1 wire circuit from drive controller terminal "10" to TB37. 0V Repair or replace the steer microswitch on the the drive controller OR consult Genie Industries Service Department. 20V or more Press down the foot switch and press the steer rocker switch in the RIGHT direction. Check voltage on TB19. Press down the foot switch and press the steer rocker switch in the RIGHT direction. Check voltage at terminal "10" on the drive controller. 0V Repair open in grn/wht #19 wire circuit with diode from TB37 to TB19 OR replace the diode. 20V or more Press down the foot switch and press the steer rocker switch in the RIGHT direction. Check voltage on the blu/blk #37 wire at the steer right directional valve coil (item CJ). 0V Repair open in blu/blk #37 wire circuit from TB37 to the steer right directional valve coil OR repair open in brn ground wire circuit to the function manifold. 20V or more Disconnect the blu/blk #37 wire to the steer right directional valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace steer right directional valve coil. 23 to 25 ohms Continued on the next page. 5 - 98 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 27 Continued from the previous page. function Exchange the steer operates directional valve (item CJ) with turntable rotate directional valve (item CX). Test the steer left function. Replace defective directional valve. function inoperative Install a 0 to 5000 PSI (345 bar) pressure gauge at the quick disconnect coupling on the function manifold. Press down the foot switch and press the steer rocker switch in the RIGHT direction and check the pressure. 3200 PSI Check for mechanical restrictions keeping the steer right function from operating OR the 0.450" orifice (item CN) may be plugged OR repair or replace the steer cylinder OR consult Genie Industries Service Department. less than 3200 psi Repair or replace the steer cylinder OR the function manifold may have an internal defect. Consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 99 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 28 All Drive Functions Inoperative, All Other Functions Operate Normally function Turn key switch to operates platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and hold the drive enable toggle switch TS9 to either side and move the drive controller in the FORWARD direction. (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) Be sure the unit is in the fully stowed position with the boom located between the drive tires. Press down the foot switch and check voltage at TB16. 20V or more 0V function inoperative Press down the foot switch and check voltage at TB12. Be sure the battery packs are properly connected and fully charged. 0V 20V or more Z-34/22 before serial number 153 and Z34/22N before serial number 304: Repair open in org/red wire circuit from TB16 to "+" terminal on the drive controller. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Repair open in org/red wire circuit from TB16 to CR5 OR repair open in ground wire circuit from CR5 to ground OR repair open in blu/wht wire circuit from center pole at TS9 to CR5 OR repair open in wire circuit from CR5 to terminal "+" on the drive controller OR replace CR5. Repair open in wire circuit from TB12 to LS3 OR repair open in wire circuit from TB16 to LS3 OR replace LS3. Repair open in blu/wht-3 wire circuit from drive enable toggle switch to TB12 OR consult Genie Industries Service Department. Check voltage from Bterminal on the motor controller to input side of 500A fuse F1. less than Repair open in power 48V cable from battery packs to F1 OR ground cable to B- terminal on the motor controller. 48V or more Continued on the next page. 5 - 100 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 28 Continued from the previous page. Check voltage on output side of 500A fuse F1. 0V Replace 500A F1. 48V or more Check voltage on the positive cable at input side of PR1. 0V Repair open in positive cable from output terminal of 500A fuse F1 to input side of PR1. 48V Press down the foot switch and move the drive controller in the FORWARD direction and check voltage at the positive cable on output side of PR1. 0V Repair open in wire circuit from terminal #1 on the motor controller to PR1 OR repair open in the ground wire circuit from PR1 to ground OR replace PR1 contacts OR replace PR1 OR consult Genie Industries Service Department. 48V Block the steer wheels and raise the machine so the drive tires are off the ground. Place blocks under the drive chassis for support. Disconnect wht wire on forward/ reverse contactor PR2. With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position, press down the foot switch and move the drive controller to full FORWARD direction and try to rotate the drive tires by hand. Note: this will require 2 people. tires don't move Go to Chart 28A, Brake Function Inoperative. tires move Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 101 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 28 Continued from the previous page. less Connect wht wire to than forward/reverse 48V contactor PR2. Press down the foot switch and move the drive controller to full FORWARD direction and check voltage at positive cable on output side of PR1. Press down the foot switch and move the drive controller to full FORWARD direction and check voltage at org/blk wire on PR1. 20V or more Repair open in ground wire circuit to PR1 OR replace PR1. 0V Press down the foot switch and move the drive contoller to full FORWARD direction and check voltage at org/blk wire at TB41. 20V or more Repair open in org/blk wire circuit from TB41 to PR1. 0V Press down the foot switch and move the drive controller in the FORWARD direction and check voltage at terminal "X" on the drive controller. 20V or more Repair open in org/blk wire circuit from terminal "X" on the drive controller to TB41. 0V 48V or more Press down the foot switch and move the drive controller in the FORWARD direction and check voltage at terminal "+" on the drive controller. 20V or more Repair or replace the drive controller. 0V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Repair open in power circuit from drive enable toggle switch TS9 to TB12 to LS3 to TB16 to "+" terminal on the drive controller. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Repair open in power circuit from drive enable toggle switch TS9 to TB12 to LS3 to TB16 to CR5 to the drive controller OR replace CR5 OR consult Genie Industries Service Department. Continued on the next page. 5 - 102 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 28 Continued from the previous page. Press down the foot switch and move the drive controller in the FORWARD direction and check voltage at terminal B+ on the motor controller. 0V Repair open in positive cable from PR1 to terminal B+ on the motor controller. 48V or more Press down the foot switch and move the drive controller in the FORWARD direction and check voltage at A1 terminal on the left drive motor. 0V Repair open in positive cable from PR1 to terminal A1 on the left drive motor. 48V or more Press down the foot switch and move the drive controller in the FORWARD direction and check voltage on terminal #1 on the motor controller. 0V Repair open in org/blk wire circuit from TB41 to terminal #1 on the motor controller. 20V or more Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 103 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 28 Continued from the previous page. Check voltage at terminal #3 on the motor controller. Voltage should ramp up from 0V to 5V. bad Press down the foot switch and slowly move the drive controller from neutral to full stroke in the FORWARD direction and check voltage on TB3. Voltage should ramp up from 0V to 5V. good Repair open in red/wht wire circuit from TB3 to terminal #3 on the motor controller. bad good Z-34/22 before serial number 153 and Z34/22N before serial number 304: Press down the foot switch and slowly move the drive controller from neutral to full stroke in the FORWARD direction and check voltage at terminal "A" on the drive controller. Voltage should ramp up from 0V to 5V. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Press down the foot switch and slowly move the drive controller from neutral to full stroke in the FORWARD direction and check voltage at terminal "D" on the drive controller. Voltage should ramp up from 0V to 5V. good Z-34/22 before serial number 153 and Z34/22N before serial number 304: Repair open in red/wht wire circuit from terminal "A" at the drive controller to TB3 to #3 terminal on the motor controller. Z-34/22 after serial number 152 and Z34/22N after serial number 303: Repair open in red/wht wire circuit from terminal "D" at the drive controller to TB3 to #3 terminal on the motor controller. bad Adjust the drive controller OR refer to Chart 33 OR repair or replace the drive controller OR consult Genie Industries Service Department. Continued on the next page. 5 - 104 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 28 Continued from the previous page. Disconnect wht wire on the forward/reverse contactor PR2. Connect a volt meter to terminals B+ and M- on the motor controller. Press down the foot switch and slowly move the drive controller from neutral to full stroke in the FORWARD direction. Voltage should ramp up from 0V to 48V. bad Replace the motor controller. good Connect wht wire on forward/reverse contactor PR2. Connect a volt meter to terminals B+ and M- on the motor controller. Press down the foot switch and slowly move the drive controller from neutral to full stroke in the FORWARD direction. Voltage should ramp up from 0V to 48V. bad Disconnect the battery packs from the machine and disconnect the positive cable from terminal A2 on the motor controller. Using an ohmmeter, check resistance in both directions across terminals A2 and B+ on the motor controller. Resistance should be high in one direction and low in the other. bad Replace motor controller. good good Repair or replace the bad motor OR consult Genie Industries Service Department. Repair open in cable circuit from the motor controller to PR2 to the drive motors OR repair open in the ground wire circuit from PR2 coils to ground OR repair or replace PR2 OR repair or replace the bad motor OR consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 105 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 28A Brake Function Inoperative (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position, press down the foot switch and move the drive controller in the FORWARD direction until the first micro switch activates. Check voltage at TB19. Be sure the drive hubs are not disengaged 0V Press down the foot switch and move the drive controller in the FORWARD direction until the first micro switch activates and check voltage at TB47. Repair open in grn/wht wire circuit with diode from pressure switch (item K) to TB19 OR replace pressure switch OR repair open in wire circuit from TB47 to the brake release valve N.C. (item K) to pressure switch. 0V Press down the foot switch and move the drive controller in the FORWARD direction until the first micro switch activates and check voltage at TB41. Be sure the remote brake release is removed. 20V or more 20V or more Repair open in org/blk wire circuit with diode from TB41 to TB47 OR replace diode. 0V Press down the foot switch and move the drive controller in the FORWARD direction until the first micro switch activates and check voltage at terminal "X" on the drive controller. 20V or more 20V or more Repair open in org/blk wire circuit from terminal "X" on the drive controller to TB41. 0V Press down the foot switch and move the joystick in the FORWARD direction until the first micro switch activates and check voltage at terminal "+" on the drive controller. 0V Repair open in power circuit from drive enable toggle switch TS9 to TB12 to LS3 to TB16 to terminal "+" on drive controller OR replace LS3 OR consult Genie Industries Service Department. 20V or more Repair or replace drive controller. Consult Genie Industries Service Department. Continued on the next page. 5 - 106 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 28A Continued from the previous page. Press down the foot switch and move the drive controller in the FORWARD direction until the 1/2 stroke micro switch activates and check voltage at red/wht and ground wires on 1/2 stroke brake release valve (item H). 0V Press down the foot switch and move the drive controller in the FORWARD direction until the 1/2 stroke micro switch activates and check voltage at TB29. 20V or more Repair open in red/wht wire circuit from TB29 to the brake release valve. 0V Press down the foot switch and move the drive controller in the FORWARD direction until the 1/2 stroke micro switch activates and check voltage at red/wht wire on 1/2 stroke micro switch on drive controller. 20V or more Repair open in red/wht wire with diode from 1/2 stroke micro switch on drive controller to TB29. 20V or more 0V Repare or replace drive controller OR consult Genie Industries Service Department. Disconnect red/wht #29 and ground wires from 1/2 stroke brake release valve coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace brake release valve coil. 22 to 24 ohms Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 107 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 28A Continued from the previous page. Press down the foot switch and move the drive controller in the FORWARD direction until the 1/2 stroke micro switch activates. Check voltage at red wire on brake release valve N.C. (item L). 0V Repair open in red #47 wire circuit from TB47 to pressure switch to brake release valve N.C. OR repair open in ground wire circuit from brake release valve N.C. coil to ground. 20V or more Disconnect the wires from the brake release valve N.C. coil. Test the resistance of the valve coil. See Repair Section. 0 or infinite ohms Replace brake release valve N.C. coil. 22 to 24 ohms Connect an ammeter in series with wht/red wire and brake proportional valve coil (item N). Press down the foot switch and move the drive controller in the FORWARD direction until the 1/2 stroke micro switch activates. Does the amperage increase proportionally from 0.10 amps to 0.90 amps at 1/2 stroke of drive controller? no Disconnect the wires from the brake proportional valve coil. Test the resistance of the proportional valve coil (item N). See Repair Section. 18 to 20 ohms 0 or infinite ohms Replace brake proportional valve coil. Adjust drive controller (See Repair Section) OR repair open in wht/ red-1 wire circuit from Z-34/22 before serial number 153 and Z34/22N before serial number 304: terminal "A" on drive controller to TB32 Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: terminal "B" on drive controller to TB32 OR repair open in the ground wire circuit to the proportional brake release valve coil OR repair or replace drive controller OR consult Genie Industries Service Department. yes Continued on the next page. 5 - 108 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 28A Continued from the previous page. Press down the foot switch and move the drive controller in the FORWARD direction to full stroke and check voltage at TB19. 20V Install a 0 to 3000 psi (0 to 207 bar) pressure gauge at the quick disconnect coupling on the function manifold. Press down the foot switch and move the drive controller in the FORWARD direction and check pressure. 1200 psi Replace pressure switch (item K) OR consult Genie Industries Service Department. less than 1200 psi 0V Install a 0 to 3000 psi (0 to 207 bar) pressure gauge at the quick disconnect coupling on the function manifold. Press down the foot switch and move the drive controller in the FORWARD direction and check pressure. Replace brake release valve half stroke (item G) OR replace brake proportional valve OR consult Genie Industries Service Department. less than Replace pressure switch 1200 psi OR consult Genie Industries Service Department. 1200 psi Check for mechanical restriction keeping drive function from operating OR consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 109 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 29 All Drive Functions Inoperative, all Other Functions Operate Normally (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Troubleshooting drive function faults may also be accomplished by using the hand-held pendant motor controller programmer (Genie part number 56303). Block the steer wheels and raise the machine so the drive tires are off the ground. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and move the drive controller in either direction. Have someone try to rotate the drive tires by hand. Note: this will require 2 people. Press down the foot switch and move the drive contoller in the FORWARD direction. Check voltage at terminal #5 on the drive controller. Press down the foot switch and check voltage on terminal #4 on the drive controller. 0V Replace the drive controller. 20V or more 0V Repair open in the wht-1 wire circuit from terminal #4 on the drive controller to TB30 to pin 10 on the motor controller harness connector. 20V or more 0V Press down the foot switch and move the drive controller in the REVERSE direction. Check voltage on terminal #3 on the drive controller. 0V Replace the drive controller. 20V or more Press down the foot switch and move the drive controller in the REVERSE direction. Check voltage at pin 11 on the motor controller harness connector. Be sure the machine is not in the free wheel configuration. 5 - 110 20V or more Press down the foot switch and move the drive controller in the FORWARD direction. Check voltage at pin 10 on the motor controller harness connector. Be sure the batteries are properly connected and fully charged. Be sure the unit is in the fully stowed position with the boom located between the non-steer end tires. Go to Chart 30, Brake Release Function Inoperative. tires move Be sure to check the motor controller status indicator light on the ground control box or on the motor controller. If the motor controller status indicator light is flashing a fault code, refer to the fault code chart at the beginning of this section. Be sure the circuit breakers and fuses are not tripped or blown. tires don't move Continued on the next page. 0V Repair open in the wht/ blk-1 wire from terminal #3 on the drive controller to TB31 to pin 11 on the motor controller harness connector. 20V or more See Chart 29A, Motor Controller Fault Code 21: Throttle Fault. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 29 Continued from the previous page. Press down the foot switch and move the drive controller in either direction. Check voltage at TB16. 20V or more Repair open in org/red wire circuit from TB16 to terminal #5 on the drive controller. 0V Press down the foot switch and move the drive controller in either direction. Check voltage at terminal #13 on LS3. 20V or more Repair open in red-5 wire circuit from terminal #13 on LS3 to TB16. 0V Press down the foot switch and move the drive controller in either direction. Check voltage at terminal #14 on LS3. 20V or more Replace LS3. 0V Press down the foot switch and move the drive controller in either direction. Check voltage at TB12. 20V or more Repair open in blk-5 wire circuit from TB12 to terminal #14 on LS3. 0V Press down the foot switch and move the drive controller in either direction. Check voltage at the center terminal at TS15. Press down the foot switch and move the drive controller in either direction. Check voltage at terminal #2 at the motor controller. 20V or more 20V or more Repair open in blu/wht-3 wire circuit from the center terminal at TS15 to TB12. Repair open in blu/wht #12 wire circuit from terminal #2 at the motor controller to TB12. 0V Replace the motor controller OR contact Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 111 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 29A Motor Controller Fault Code 21: Throttle Fault (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Troubleshooting drive function faults may also be accomplished by using the hand-held pendant motor controller programmer (Genie part number 56303). Be sure to check the motor controller status indicator light on the ground control box or on the motor controller. If the motor controller status indicator light is flashing a fault code, refer to the fault code chart at the beginning of this section. Be sure the circuit breakers and fuses are not tripped or blown. Be sure the battery packs are properly connected and fully charged. Turn key switch to the OFF position and disconnect motor controller harness connector from the motor controller. Connect the leads from an ohmmeter to pins 14 and 16 on the connector (pins 14 and 16 are the wht/red and red/wht wires). Check the resistance. less than 4000 ohms Repair open in the wire circuit from the potentiometer to terminals1 and 2 on the drive controller OR replace the drive controller. greater than 7500 ohms Repair open in the ground wire circuit in the red/wht or wht/red wires from pins 14 and 16 to terminals #1 and #2 on the drive controller OR replace the drive controller. no Replace the drive controller. 4000 to 7500 ohms Block the steer wheels and raise the machine so drive tires are off the ground. With the leads from an ohmmeter connected to pins 14 and 16 on the connector, move the drive controller slowly to full stroke in both the FORWARD and REVERSE directions while watching the ohm meter. Does the resistance ramp smoothly down to 10 ohms or less in both directions? Note: This will require 2 people. yes Begin troubleshooting from the beginning of the chart OR consult Genie Industries Service Department. Be sure the machine is not in the free wheel configuration. Be sure the unit is in the fully stowed position with the boom located between the non-steer end tires. 5 - 112 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 29B Motor Controller Fault Code 32: Main Contactor Welded (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Troubleshooting drive function faults may also be accomplished by using the hand-held pendant motor controller programmer (Genie part number 56303). Be sure to check the motor controller status indicator light on the ground control box or on the motor controller. If the motor controller status indicator light is flashing a fault code, refer to the fault code chart at the beginning of this section. Disconnect the battery packs from the machine. Visually inspect the contacts on PR1. Are the contacts stuck closed? Test the resistance between terminals Mand B+ on the motor controller. Note: An ohmmeter capable of reading 1 ohm or less is needed for this test. 1 ohm or less Remove the grn wire from PR1. Check continuity from the grn wire that was just removed from PR1 to the B- terminal on the motor controller. Part No. 36540 Test the resistance more than between terminals A1 1 ohm and A2 on each drive motor. Is the resistance 1 ohm or less on each drive motor? no Replace the drive motor that has a resistance of more than 1 ohm. yes Repair open in motor armature cables from terminals M- and B+ on the motor controller to each drive motor. less than Remove the motor controller harness 500 kilohms connector from the motor controller. Check continuity from the grn wire that was just removed from PR1 to the B- terminal on the motor controller. less than Repair open in the 500 kilohms ground wire circuit from pin 17 on the motor controller harness connector to PR1. more than 500 kilohms more than 500 kilohms Be sure the machine is not in the free wheel configuration. Be sure the unit is in the fully stowed position with the boom located between the non-steer end tires. Replace drive contactor PR1 contacts OR replace the drive contactor PR1. no Be sure the circuit breakers and fuses are not tripped or blown. Be sure the battery packs are properly connected and fully charged. yes Check continuity from pin 17 (grn wire) on the motor controller to the B- terminal on the motor controller. less than 500 kilohms Replace the motor controller. more than 500 kilohms Please begin troubleshooting from beginning of chart. Please begin troubleshooting from beginning of chart. Genie Z-34/22 & Genie Z-34/22N 5 - 113 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 29C Motor Controller Fault Code 34: Missing Main Contactor OR Main Contactor Did Not Close (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Block the steer wheels and raise the machine so drive tires are off the ground. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and check the voltage at pin 1 on the motor controller harness connector. Repair open in org/red wire circuit with diode from TB42 to pin 1 on the motor controller harness connector OR replace the diode. Check voltage at TB3. 0V Repair open in red/wht wire circuit from TB3 to platform Emergency Stop button P2. 0V Repair open in red/wht wire from TB3 to terminal #85 on CR2. 0V Repair open in brn ground wire circuit from terminal #85 on CR2 to ground OR repair open in wire from terminal #87 on CR2 to terminal #30 on CR1 OR repair open in org/red #CR2 from the 10A fuse F5 to terminal #30 on CR2 OR replace CR2. 0V Repair open in brn ground wire from terminal #86 on CR1 to ground OR repair open in red/wht wire from TB3 to terminal #85 on CR1 OR replace CR1. 24V Check the voltage at terminal #30 on CR1. 48V 48V Check the voltage at terminal #87 on CR1. 48V Be sure the battery packs are properly connected and fully charged. Repair open in org/red wire from terminal #87 on CR1 to TB42. Be sure the machine is not in the free wheel configuration. 5 - 114 48V 0V Check voltage at terminal #86 on CR2. Be sure the circuit breakers and fuses are not tripped or blown. Be sure the unit is in the fully stowed position with the boom located between the non-steer end tires. Press down the foot switch and check the voltage at TB42. 24V Troubleshooting drive function faults may also be accomplished by using the hand-held pendant motor controller programmer (Genie part number 56303). Be sure to check the motor controller status indicator light on the ground control box or on the motor controller. If the motor controller status indicator light is flashing a fault code, refer to the fault code chart at the beginning of this section. 0V Continued on the next page. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 29C Continued from the previous page. Check voltage on the battery cable on the input side of PR1. 0V Repair open in cable circuit from battery packs to 500A fuse F4 OR replace the 500A fuse F4. 0V Repair open in blu/wht wire from TB12 to terminal "A" on the joystick controller. 48V Press down the foot switch and check voltage at TB12. 20V or more Press down the foot switch and check voltage at pin 2 on the motor controller harness connector. 0V Repair open in blu/wht wire from TB12 to pin 2 on the motor controller harness connector. 20V or more Turn key switch to the OFF position. Wait for 5 seconds and turn the key switch to platform controls. Do not press down the foot switch. Check voltage at the grn wire on PR1. 0V Check voltage on the org/red wire at PR1. 48V Replace PR1. 0V Repair open in org/red wire circuit from TB42 to PR1. 48V Remove the diode from PR3 and install it onto PR1 with the band on the diode aligned with the org/red-42 wire. Push in the Emergency Stop button to the OFF position and wait for 5 seconds, then pull out the Emergency Stop button to the ON position. Press down the foot switch and test the drive function. Does the machine drive? yes Install a new diode onto PR3 with the band on the diode aligned with the red-27 wire. no Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 115 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 29C Continued from the previous page. Check voltage between the terminals B+ and Bon the motor controller. Note the voltage. Press down the foot switch and check voltage between pin 1 on the motor controller harness connector and terminal B-. Is the voltage within 1V of the first reading? yes no Disconnect the batteries from the machine. Remove the PR1 mounting fasteners. Clean all 4 contact tips until they are clean and smooth. Install the contactor onto the power panel and connect the batteries. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and test the drive function. Does the machine drive? yes Drive function should be operating normally. If it does not, begin troubleshooting from beginning of chart. no Replace the motor controller. Repair open in grn wire from PR1 to pin 17 OR replace PR1 OR test the motor controller. See Repair Section. 5 - 116 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 30 Brake Release Function Inoperative (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Be sure all other functions operate normally. Troubleshooting brake release faults may also be accomplished by using the hand-held pendant motor controller programmer (Genie part number 56303). Be sure to check the motor controller status indicator light on the ground control box or on the motor controller. If the motor controller status indicator light is flashing a fault code, refer to the fault code chart at the beginning of this section. Be sure the battery packs are properly connected and fully charged. Be sure the circuit breakers and fuses are not tripped or blown. Be sure the unit is in the fully stowed position with the boom located between the non-steer end tires. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and check the status indicator light on the motor controller to see if there is a fault. Is there a fault? yes Refer to the fault code chart at the beginning of this section to determine the cause of the fault. no Block the steer wheels and raise the machine so drive tires are off the ground. With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position, press down the foot switch and move the drive controller in either direction and check voltage at TB41. 0V Press down the foot switch and move the drive controller in either direction and check the voltage at TP41. 0V See Chart 38, Drive Enable System Inoperative. 24V Repair open in org/blk wire from TB41 to TP41. 24V Press down the foot switch and move the drive controller in either direction and check voltage at terminal #30 on CR5. 0V Repair open in org/blk #41 wire from TB41 to terminal #30 on CR5. 24V Press down the foot switch and move the drive controller in either direction and check voltage at terminal #87 on CR5. 0V Do not press down the foot switch. Check voltage at the red/blk wire on pin 20 of the motor controller harness connector. 0V Repair open in org/red wire circuit from TB42 to terminal #85 on CR5 OR repair open in red/blk wire from pin 20 to terminal #86 on CR5 OR replace CR5. 48V 24V Continued on the next page. Press down the foot switch and check voltage at the red/blk wire on pin 20 of the motor controller harness connector. 0V Replace the motor controller. 24V Replace CR5. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 117 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 30 Continued from the previous page. Press down the foot switch and move the drive controller in either direction and check voltage at TB48. 0V Repair open in red/wht #48 wire from terminal #87 on CR5 to TB48 OR replace diode. 24V Insert a jumper wire between TB48 and TB19. Press down the foot switch and move the drive controller in either direction. Does the power unit turn on? yes Remove the pressure switch plug and place a jumper between terminals 1 and 2 on the plug. Press down the foot switch and move the drive controller in either direction. Does the power unit turn on? yes Replace the pressure switch. no Repair open in red/wht #48 wire from TB48 through red/wht wire circuit to pressure switch, then grn/wht #19 wire with diode to TB19 OR replace the diode. no Press down the foot switch and move the drive controller in either direction. Check voltage on the red/wht wires on the brake release valve coils (items G and K). 0V Repair open in red/wht wires from TB48 to the brake release valve coils (items G and K). 24V Remove the brake release valve coil and clean the coil contact rings on both ends of the coil. Then install the coil onto the valve cartridge. Drive the machine. Do the brakes release? yes Drive and brake release functions should be operating normally. If they do not, begin troubleshooting from beginning of chart. no Continued on the next page. 5 - 118 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts CHART 30 Continued from the previous page. Check continuity from the brake release valve cartridge to the ground bolt inside the ground control box. no continuity Repair open in brn ground wire circuit from the function manifold to the ground bolt inside the ground control box. continuity Disconnect the wires from each of the valve coils and check the resistance of the valve coils. See Repair Section. 0 or infinite ohms Replace defective valve coil. 22 to 25 ohms Consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 119 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 31 Drive Forward Function Inoperative (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the footswitch and move the drive controller in the FORWARD direction and check voltage on wht/blk #31 wire on forward contactor PR2. 20V or more 0 or Remove wht/blk #31 and infinite ground wires from PR2 ohms coil and check resistance of forward coil. Repair or replace PR2. 40 ohms Repair or replace PR2 contacts OR repair open in ground wire circuit OR consult Genie Industries Service Department. 0V Press down the foot switch and move the drive controller in the FORWARD direction and check voltage on TB31. 20V or more Repair open in white/blk #31 wire circuit from TB31 to the forward contactor. 20V or more Repair open in wire circuit from wht/blk-1 wire on micro switch on drive controller to TB31. 0V Press down the foot switch and move the drive controller in the FORWARD direction and check voltage on wht/ blk-1 wire on micro switch on the drive controller. 0V Repair or replace micro switch on the drive controller OR drive controller cams are out of adjustment. Consult Genie Industries Service Department. 5 - 120 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 32 Drive Reverse Function Inoperative (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) Be sure key switch is in the appropriate position. Be sure the Emergency Stop buttons are pulled out to the ON position. Be sure the battery packs are properly connected and fully charged. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and move the drive controller in the REVERSE direction and check voltage on wht #30 wire on forward/ reverse contactor PR2. 20V or more Remove wht #30 and ground wires from PR2 coil and check resistance of reverse coil. 0 or infinite ohms Repair or replace PR2. 40 ohms Repair or replace PR2 contacts OR repair open in ground wire circuit OR consult Genie Industries Service Department. 0V Press down the foot switch and move the drive controller in the REVERSE direction and check voltage on TB30. 20V or more Repair open in wht #30 wire circuit from TB30 to forward/reverse contactor. 20V or more Repair open in wire circuit from wht-1 wire on micro switch on the drive controller to TB31. 0V Press down the foot switch and move the drive controller in the REVERSE direction and check voltage on wht-1 wire on micro switch on the drive controller. 0V Repair or replace micro switch on the drive controller OR drive controller cams are out of adjustment. Consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 121 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 33 Machine Will Not Drive At Full Speed (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) Be sure the unit is in the fully stowed position with the boom located between the nonsteer end tires. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Check voltage on "R" terminal on the drive controller. 0V Check voltage on TB40. 20V or more 20V or more Adjust the drive controller (See Repair Section) OR repair or replace drive controller OR consult Genie Industries Service Department. Repair open in org-1 wire circuit from TB40 to "R" terminal on the drive controller. 0V Check voltage on TB23. Be sure the battery packs are properly connected and fully charged. 0V 20V or more Repair open in wire circuit from Z-34/22 before serial number 153 and Z34/22N before serial number 304: TB23 to LS1 to TB49 to LS2 to TB40. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: TB23 to LS1 to TB49 to LS2 to TB52 to LS4 to TB40. Repair open in the wht-2 wire circuit with diode from the platform Emergency Stop button to TB23 OR replace the diode. 5 - 122 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 34 Machine Will Not Drive At Full Speed (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Be sure all other functions operate normally. Be sure the boom is in the stowed position with the primary boom fully retracted. Be sure the primary boom extension limit switch (LS1) is being activated when the primary boom is retracted. Be sure the primary boom and secondary boom limit switches (LS2 and LS3) are not being activated when the primary and secondary booms are in the stowed position. Be sure the battery packs are properly connected and fully charged. Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Check the status indicator light on the motor controller to see if there is a fault. Is there a fault? yes Refer to the fault code chart at the beginning of this section to determine the cause of the fault. no Check voltage at TB22. 0V Repair open in blk #22 wire from key switch to TB22. 24V Check voltage at the wht-7 wire on the input side of LS1. 0V Repair open in wht-7 wire from TB22 to the input side of LS1. 24V Check voltage at TB49. 0V 24V Check voltage at the blk-6 wire on the input side of LS2. 0V Check to make sure LS1 is being activated when the primary boom is retracted OR repair open in blk-7 wire from the output side of LS1 to TB49 OR replace LS1 contacts OR replace LS1. Repair open in blk-6 wire from TB49 to the input side of LS2. 24V Check voltage at TB50. 24V 0V Check to make sure LS2 is not being activated when the primary boom is in the stowed position OR repair open in wht-6 wire from the output side of LS2 to TB50 OR replace LS2 contacts OR replace LS2. Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 123 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 34 Continued from the previous page. Check voltage at the wht-8 wire on the input side of LS4. 0V Repair open in wht-8 wire from TB50 to the input side of LS4. 24V Check voltage at TB40. 0V 24V Check voltage at pin 3 on the motor controller harness connector. 0V Check to make sure LS4 is not being activated when the secondary boom is in the lowered position OR repair open in blk-8 wire circuit from the output side of LS4 to TB40 OR replace LS4 contacts OR replace LS4. Repair open in org #40 wire circuit from TB40 to pin 3 on the motor controller harness connector. 24V Test the motor controller (see Repair Section) OR consult Genie Industries Service Department. 5 - 124 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 35 Machine Drives At Full Speed With Platform Raised Or Extended (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) Remove the machine from service immediately. Be sure the wiring to the limit switches is intact and shows no signs of damage or corrosion. Be sure the primary boom drive limit switch is being activated by the cam on the boom when the primary boom is raised. Be sure the secondary boom drive limit switch is being activated by the secondary boom compression arm when the secondary boom is raised. Part No. 36540 Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. With the primary boom raised above the limit switch LS2, check voltage on TB49. 20V or more Repair or replace LS2 OR check for mechanical restriction keeping LS2 activated. 20V or more Repair or replace LS1 OR check for mechanical restriction keeping LS1 activated. 20V or more Repair or replace LS4 OR check for mechanical restriction keeping LS4 activated . 0V Adjust drive controller OR repair or replace drive controller OR consult Genie Industries Service Department. 0V Extend the primary boom past the limit switch LS1 and check voltage on Z-34/22 before serial number 153 and Z34/22N before serial number 304: TB40. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: TB52. 0V Adjust drive controller OR repair or replace drive controller OR consult Genie Industries Service Department. 0V Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Raise the secondary boom above the limit switch LS4 and check voltage on TB40. 0V Adjust drive controller OR repair or replace drive controller OR consult Genie Industries Service Department. Genie Z-34/22 & Genie Z-34/22N 5 - 125 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 36 Machine Drives At Full Speed With Platform Raised Or Extended Turn key switch to ground controls and pull both Emergency Stop buttons out to the ON position. Check the status indicator light on the motor controller to see if there is a fault. Is there a fault? yes Refer to the fault code chart at the beginning of this section to determine the cause of the fault. no (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Remove the machine from service immediately. Be sure the wiring to the limit switches is intact and shows no signs of damage or corrosion. With the boom in the lowered position, check voltage at pin 3 on the motor controller harness connector. 0V Refer to Chart 34. 24V Raise the primary boom approximately 10 feet (3m) and check voltage at pin 3 on the motor controller harness connector. 24V Check for proper activation of primary boom limit switch LS2 OR replace LS2 contact OR replace LS2. 0V Be sure the primary boom drive limit switch is being activated by the cam on the boom when the primary boom is raised. Be sure the secondary boom drive limit switch is being activated by the secondary boom compression arm when the secondary boom is raised. Lower the primary boom to the lowered position and raise the secondary boom approximately 10 feet (3m). Check voltage at pin 3 on the motor controller harness connector. 24V Check for proper activation of secondary boom limit switch LS4 OR replace LS4 contact OR replace LS4. 0V Lower the secondary boom to the lowered position and extend the primary boom approximately 12 inches (30 cm). Check voltage at pin 3 on the motor controller harness connector. 0V Check for proper activation of primary boom extend limit switch LS1 OR replace LS1 contact OR replace LS1. 24V Replace the motor controller OR consult Genie Industries Service Department. 5 - 126 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 37 Drive Enable System Is Malfunctioning (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) Be sure the machine is in the stowed position with the turntable rotated so the boom is in between the non-steer wheels. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and check voltage at TB12. 0V Repair open in blu/wht-3 wire circuit from TB12 to center pole of TS9. 0V Repair open in blk #12 wire circuit from TB12 through normally closed contact of LS3 to TB16. 24V Press down the foot switch and check voltage at TB16. 24V Press down the foot switch and check voltage at terminal "+" on drive controller. 0V Be sure all other functions operate normally. 24V Rotate the boom past either non-steer wheel and check voltage on TB16. 24V Z-34/22 before serial number 153 and Z34/22N before serial number 304: Repair open in org/red-3 wire circuit from TB16 to terminal "+" on the drive controller. Z-34/22 from serial number 153 to 1733 and Z-34/22N from serial number 304 to 2226: Repair open in org/red wire circuit from TB16 to CR5 OR repair open in ground wire circuit from CR5 to ground OR repair open in blu/wht wire circuit from center pole at TS9 to CR5 OR repair open in wire circuit from CR5 to terminal "+" on the drive controller OR replace CR5. Repair or replace LS3. 0V Continued on the next page. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 127 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing CHART 37 Continued from the previous page. Press down the foot switch and hold the drive enable toggle switch TS9 to either side and check voltage on terminal "+" on drive controller. 0V Repair open in wire circuit from drive enable toggle switch TS9 to terminal "+" on drive controller OR replace TS9 OR consult Genie Industries Service Department. 24V Adjust drive controller OR replace drive controller OR consult Genie Industries Service Department. 5 - 128 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 5 • Troubleshooting Flow Charts Chart 38 Drive Enable System Is Malfunctioning (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) Be sure the machine is in the stowed position with the turntable rotated so the boom is in between the non-steer wheels. Be sure all other functions operate normally. Turn key switch to platform controls and pull both Emergency Stop buttons out to the ON position. Press down the foot switch and check voltage at TB12. 0V Repair open in blu/wht-3 wire circuit from TB12 to the wht wire on the center terminal of TS15. 24V Press down the foot switch and check voltage at terminal #14 on the drive enable limit switch LS3. 0V Repair open in the blk-5 wire from TB12 to terminal #14 on the drive enable limit switch. 24V Rotate the boom past either non-steer wheel and check voltage on the red-5 wire at terminal #13 of the drive enable limit switch LS3. 24V Check for proper activation of drive enable limit switch LS3 when the boom is rotated past either nonsteer wheel OR replace LS3 contact OR replace LS3. 0V Press down the foot switch and check voltage on org/blk wire at terminal #5 on drive controller. 24V Replace drive controller. 0V Press down the foot switch and check voltage at the wht wire on the center terminal on TS15. 0V Repair open in wht wire from terminal #6 on the drive controller to the center terminal on TS15. 24V Press down the foot switch and hold the drive enable toggle switch TS15 to either side and check voltage at terminal #5 on the drive controller. 0V Replace the drive enable toggle switch OR repair open in the wht wire from TS15 to center terminal on TS1. 24V Begin troubleshooting from the beginning of the chart OR consult Genie Industries Service Department. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 5 - 129 Section 5 • Troubleshooting Flow Charts First Edition • Third Printing Chart 39 Remote Brake Release Inoperative (Z34/22 before serial number 3578 and Z34/22N before serial number 4261) Be sure all other functions operate normally. Be sure the battery packs are properly connected and fully charged. Pull the Emergency Stop button at ground controls out to the ON position. Check voltage at the input side of the remote brake release jack J1 on the ground control panel. 0V Repair open in red wire circuit from input side of the key switch to the input side of the remote brake release jack. 20V or more With the remote brake release switch plugged into the remote brake release jack on the ground control panel, press down the remote brake release button and check voltage at the output side of the plug. 0V Replace remote brake release button OR replace the remote brake release jack. 20V or more Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: Activate remote brake release and check voltage at TB46 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Activate remote brake release and check voltage at TB48. 0V Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: Repair open in red/wht wire circuit from the output side of the remote brake release jackto TB46 Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226: Repair open in red/wht wire circuit from the output side of the remote brake release jack to TB48. 20V or more Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: Activate remote brake release and check voltage at TB47. 0V Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227: Repair open in red/wht wire circuit with diode from TB46 to TB47 OR replace the diode. 20V or more Remote brake release function should be operating. Begin troubleshooting from the beginning of this chart. 5 - 130 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. Electrocution/burn hazard. Contact with electrically charged circuits may result in death or serious injury. Remove all rings, watches and other jewelry. Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Hydraulic Schematics Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Before Troubleshooting: General Repair Process Read, understand and obey the safety rules and operating instructions printed in the Genie Z-34/22 & Genie Z-34/22N Operator's Manual. Identify symptoms Malfunction discovered Be sure that all necessary tools and test equipment are available and ready for use. problem still exists Return to service Part No. 36540 Troubleshoot problem solved Genie Z-34/22 & Genie Z-34/22N Inspect and test Perform repair 6-1 Section 6 • Schematics First Edition • Third Printing Electrical Components Item Description Genie Part Number Manufacturer Manufacturer Part Number Qty Part Number AP1, AP2 ....... Anderson connector ............ 19436 ............. Anderson ............................. 63325-G1 ....................... 2 BAT1 .............. Battery, 6V DC, 350 AH ....... 44820 ............. Allied Battery Co .................. L-16GH .......................... 8 BCI ................. Battery charge indicator ....... 23868 ............. Curtis Instruments ................ 13508010 ....................... 1 BP1 ................ Rotational Controller ............ 36557 ............. OEM Controls ...................... RS10T4331 .................... 1 CB1 ................ Circuit breaker .................... 375785 ............ ETA ...................................... 45-700-IG1-P10 ............. 1 CR .................. Relay, DPDT, 24V DC ......... 42616 ............. Potter and Brumfield ............ K10P 11D15-24 ............. 3 CR .................. Relay, SPST, 24V DC .......... 56302 ............. Potter and Brumfield ............ VF4-15H11-CO5 ............ 9 CR .................. Relay, DPDT, 24V DC ......... 36354 ............. Omron .................................. N/A ................................. 1 Diode .............. Diode, 6 amp, 200 PIV ......... 45782 ............. Motorola ............................... MOTMR752 ................. 36 DP1 ................ Joystick controller ................ 56274 ............. OEM Controls ...................... MS6M11498 ................... 1 FB .................. Flashing beacon .................. 20189 ............. ECCO Electronic Controls ... 6400X ............................. 1 F1 ................... Fuse, 500 amp ..................... 43179 ............. Buss ..................................... ANN-500 ........................ 1 F2, F3 ............. Fuse, 100 amp ..................... 36355 ............. Buss ..................................... ANN-100 ........................ 2 FS1 ................ Foot switch ........................... 13482 ............. Linemaster Switch Corp. ..... 632-S ............................. 1 H1 .................. Alarm, Warble tone .............. 45383 ............. Floyd Bell Inc. ...................... MW-09-530-Q ................ 1 H2 .................. Horn, 24V DC, 108 dB ......... 56265 ............. FIAMM ................................. 7324021 ......................... 1 H3 .................. Alarm, intermittent ................ 18963 ............. Floyd Bell Inc. ...................... XB-09-630-Q .................. 1 H4 .................. Alarm, chime tone ................ 45462 ............. Floyd Bell Inc. ...................... CH-09-525-Q ................. 1 HM .................. Hour meter ........................... 56100 ............. Curtis Instruments ................ 17305628 ....................... 1 This list continues on the next page. 6-2 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 6 • Schematics ELECTRICAL COMPONENTS Item Description Genie Part Number Manufacturer Manufacturer Part Number Qty KS1 ................ Contact - Key switch, N.O. ... 45081 ............. Telemecanique .................... ZB2-BE101 .................... 2 LS1-LS4 ......... Contact - Limit switch .......... 19491 ............. Telemecanique .................... XESP2051 ..................... 1 Level sensor .. Level sensor, 4.5° (ANSI & CSA) ............... 44586 ............. Power Comp. of Midwest ..... LS36 ............................... 1 MC1 ............... Motor controller, Curtis ........ 23314 ............. Curtis Instruments ................ 1205-205 ........................ 1 MC1 ............... Motor controller, Sepex 48V, 500 amp ...................... 56012 ............. Curtis Instruments ................ 1244-5502 ...................... 1 P1, P2 ............ Contact, N.C. ....................... 29732 ............. Telemecanique .................... ZB2-BE102 .................... 4 P3 ................... Contact, N.O. ....................... 45081 ............. Telemecanique .................... ZB2-BE101 .................... 1 PR1 ................ Relay, 180 amp .................... 19550 ............. Curtis Instruments ................ SW180 24DCCW/4 ........ 1 PR2 ................ Relay, 180 amp .................... 56434 ............. Curtis Instruments ................ SW180L 24DCCW/26 ... 1 PR3 ................ Relay, 80 amp ...................... 19549 ............. Curtis Instruments ................ SW80 24DCCW/6 ......... 1 TS1, TS51 ...... Toggle switch, DPST 2 position momentary .......... 13480 ............. Microswitch Control Inc. ...... 2NT1-8 ........................... 2 TS54 .............. Toggle switch, DPST 2 position maintained ........... 27378 ............. Microswitch Control Inc. ...... 2NT1-3 ........................... 1 TS7-TS13 and TS57-TS63 ..... Toggle switch, DPDT 3 position momentary .......... 16397 ............. Microswitch Control Inc. ...... 2NT1-7 ......................... 14 TS2, TS6, TS15, TS52, TS55, TS56 .... Toggle switch, SPDT 3 position momentary .......... 13037 ............. Microswitch Control Inc. ...... 1NT1-7 ........................... 6 TS4 ................ Toggle switch, DPDT 3 position maintained ........... 13038 ............. Microswitch Control Inc. ...... 2NT1-1 ........................... 1 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 6-3 Section 6 • Schematics First Edition • Third Printing Load Sensor Option Diagram (Z-34/22 before serial number 1734) (Z-34/22N before serial number 2227) YE T L D BLK RE WH LABEL 2 1 2 3 4 4 LOAD SENSE PCB CR5 3 1 3 2 4 5 6 LOAD SENSOR 1 2 3 1 4 5 6 7 8 9 7 8 10 11 12 6 RED/BLK 5 8 8 7 6 5 4 3 2 1 BRN RESET DISCHARGE L.V.I. OPTION SET TO "A" 7 SET TO "N" FUSE FOOT SWITCH 110 DESCRIPTION P2 P3 DP1 BP1 TS1 TS2 TS3 TS4 TS5 TS6 TS7 TS8 EMERGENCY STOP BUTTON HORN BUTTON DRIVE CONTROLLER BOOM SPEED CONTROLLER TURNTABLE ROTATE SWITCH SECONDARY BOOM SWITCH PRIMARY BOOM SWITCH EXTEND/RETRACT SWITCH PLATFORM LEVEL SWITCH PLATFORM ROTATE SWITCH JIB SWITCH AUXILIARY SWITCH TS9 L1 BCI TS18 L2 DRIVE ENABLE SWITCH DRIVE ENABLE LIGHT BATTERY CHARGE INDICATOR LIFT/DRIVE SELECT (OPTION) OVERLOAD LIGHT (OPTION) JIB BLK - FOOT SWITCH RED/BLK BRN CR6 CABLE #3 CABLE #2 BRN CABLE #1 WHT 8 6 8 7 5 6 4 2 5 3 1 7 4 2 3 1 TILT ALARM RED/BLK RED/WHT TS9 TS7 TS2 TS1 BP1 TS5 TS3 GRN L2 RED BLK/RED TS4 TS6 TS18 (OPTION) L1 BLK DP1 TS8 P3 P2 NO NC NC + BCI - L B + X D R + R BRN 6-4 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 6 • Schematics Load Sensor Option Diagram (Z-34/22 from serial number 1734 to 2060) (Z-34/22N from serial number 2227 to 2870) DESCRIPTION LABEL BLK D 2 3 4 LOAD SENSE (OPTION) 1 2 3 4 5 6 7 8 9 P3 HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB UP/DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH TS11 PRIMARY BOOM TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH L1 DRIVE ENABLE LIGHT L2 OVERLOAD LIGHT (OPTION) C F.S. JIB CABLE #2 CABLE #1 BRN RED/WHT NC WHT-FS NO WHT BRN + RED/BLK - EMERGENCY STOP BUTTON CABLE #3 BRN 1 RE GR WH N T P2 LOAD CELL WHT-FS TS15 TS12 TS10 BP1 BLK/RED TS8 TS11 TS7 RED TS13 + R L2 L NC NC 1 NO TS1 P3 Part No. 36540 2 3 4 5 6 7 8 L1 9 10 TS9 BRN GRN P2 Genie Z-34/22 & Genie Z-34/22N DP1 6-5 Section 6 • Schematics First Edition • Third Printing Load Sensor Option Diagram (Z-34/22 from serial number 2061 to 3577) (Z-34/22N from serial number 2871 to 4260) LABEL BLK RE 2 3 4 LOAD SENSE OPTION 1 2 3 4 5 6 7 8 9 HORN BUTTON DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB UP/DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM TOGGLE SWITCH TS11 PRIMARY BOOM TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY BOOM EXTEND TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH L1 DRIVE ENABLE LIGHT L2 OVERLOAD LIGHT (OPTION) C F.S. JIB CABLE #2 CABLE #1 BRN RED/WHT NC WHT-FS NO WHT BRN + RED/BLK - P3 DP1 CABLE #3 BRN T D N WH GR 1 DESCRIPTION EMERGENCY STOP BUTTON P2 LOAD CELL WHT-FS TS15 TS12 TS10 BP1 TS11 TS7 BLK/RED TS8 RED TS13 R + L2 L 6-6 NC NC 1 NO TS1 2 3 4 5 6 7 8 L1 9 10 TS9 BRN GRN P3 P2 Genie Z-34/22 & Genie Z-34/22N DP1 Part No. 36540 First Edition • Third Printing Section 6 • Schematics Power Cable Diagram (Z-34/22 before serial number 3578) (Z-34/22N before serial number 4261) + + 6V 6V AMMETER BLK - - + WHT - _ - 6V 6V + TANK SIDE BATTERY PACK + GROUND CONTROLS SIDE BATTERY PACK AC BATTERY CHARGER 6V + 6V PRIMARY LIFT PUMP - - - - + AUXILIARY LIFT PUMP BLK - + BLK RED - + RED + 6V + RED BLK AP2 - BLK (10 Ga) WHT (10 Ga) 6V + BLK RED + RED BLK BLK RED AP1 - - + + 24V PR3 PRIMARY LIFT PUMP CONTACTOR 1 PR1 F1 DRIVE 400A CONTACTOR F2 100A B- B+ M- A2 PR4 AUXILIARY LIFT PUMP CONTACTOR F3 100A 3 48V Power Cable Diagram FWD (Z-34/22 before serial number 1734) (Z-34/22N before serial number 2227) REV PR2 LEFT SIDE DRIVE MOTOR S2 A1 A2 A2 A1 S1 RIGHT SIDE DRIVE MOTOR S2 S1 + + AMMETER BLK (10 Ga) - - + WHT (10 Ga) - _ - + RED TANK SIDE BATTERY PACK + - GROUND CONTROLS SIDE BATTERY PACK AC BATTERY CHARGER + PRIMARY LIFT PUMP A1 D1 - - BLK RED BLK RED BLK 3 DIODES F1 500A F2 100A F3 100A PR1 DRIVE CONTACTOR 48V F1 B+ BLK F2 LEFT SIDE DRIVE MOTOR A2 A1 F1 F1 BLK BLK A2 A1 PR3 AUXILIARY LIFT PUMP CONTACTOR (Z-34/22 from serial number 1734 to 3577) (Z-34/22N from serial number 2227 to 4260) F2 M- + RED (10 Ga) B- - + Power Cable Diagram BLK SEPEX MOTOR CONTROLLER RED (10 Ga) AP1 - 24V BATTERY CONTROLLER PR2 PRIMARY LIFT PUMP CONTACTOR + RED - AUXILIARY LIFT PUMP A2 RED + BLK RED BLK AP2 - - D1 BLK (10 Ga) WHT (10 Ga) + + BLK + F2 RIGHT SIDE DRIVE MOTOR RED (10 Ga) Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 6-7 Section 6 • Schematics First Edition • Third Printing Power Cable Diagram (Z-34/22 after serial number 3577) (Z-34/22N after serial number 4260) RIGHT SIDE BATTERY PACK AMMETER LEFT SIDE BATTERY PACK BLK (10) _ + WHT (10) _ - + + _ _ AC BATTERY CHARGER + + BLK (2) RED (2) _ _ + + A1 PRIMARY LIFT PUMP _ D1 BLK (4) D1 _ AUXILIARY LIFT PUMP A2 + + + RED (2) BLK (2) _ _ BLK (2) RED (2) RED (2) RED (4) BLK (10) WHT (10) BLK (4) RED (4) BLK (2) AP2 + AP1 _ _ + + 24V BATTERY CONTROLLER PR2 PRIMARY LIFT PUMP CONTACTOR F1 500A F2 100A F3 100A 3 DIODES PR1 DRIVE CONTACTOR PR3 AUXILIARY LIFT PUMP CONTACTOR BLK (2) 48V CURTIS MOTOR CONTROLLER NOTES: 1. WIRE GAUGE NOTED IN PARENTHESES AFTER 2 F1 RED (10) WIRE COLOR. 2 DO NOT ROUTE POWER CABLES ACROSS B- M- F2 RED (10) B+ FRONT OF THE MOTOR CONTROLLER. DOING SO CAN AFFECT INTERNAL CURRENT SENSORS, CAUSING REDUCED MOTOR PERFORMANCE. BLK (2) F2 LEFT SIDE DRIVE MOTOR A1 A2 BLK (2) F1 F1 BLK (2) A2 A1 F2 RIGHT SIDE DRIVR MOTOR RED (10) 6-8 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 6 • Schematics Abbreviations Legend LABEL DESCRIPTION A .................. Alarm AP ............... Anderson Plug BCI .............. Battery charge indicator (option) BP ............... Boom function speed controller CB ............... Circuit breaker CR ............... Control relay DE ............... Drive enable DP1 ............. Drive proportional controller F .................. Fuse FB ................ Flashing beacon FS ................ Foot switch HM ............... Hour meter J1 ................ Brake release receptacle KS ............... Key switch L .................. Light or LED LS ................ Limit switch LVI ............... Low voltage indicator (option) OL ............... Overload light (option) P .................. Power switch PR ............... Power relay PS ............... Pressure switch TB ............... Terminal base location TP ............... Terminal platform location TS ............... Toggle switch Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 6-9 Section 6 • Schematics First Edition • Third Printing Electrical Symbols Legend BRAKE BOARD TB17 DRIVE BOARD DP1 ORG/BLK-1 A BLK GRN/BLK - X - LED X + L A R + R Wire color with cable number TB20 Horn/Alarm Drive controller (Joystick) FB RED BP1 GRN BLK/RED Flashing beacon WHT Ground supression circuit Solenoid or relay coil Terminal + Circuit breaker Boom function speed controller HM _ CR4 AP1 FORWARD REVERSE Hour meter PR2 Quick disconnect terminal BLK #21 NC NO LS3 Dual pole power relay J1 Limit switch TB21 CR4 3 T-circuits connect at terminal M- 1 PR4 Brake release jack BB+ A2 Power relay normally open TS3 Motor controller before: Z34-1737, Z34N-2227 S2 A2 Connection no terminal Toggle switch SPDT S1 PLATFORM TS6 GROUND Key switch RIGHT P3 Toggle switch DPDT PUMP KS1 (before Z34-3578 and Z34N-4261) LEFT Drive motor Circuits crossing no connection LS1 NOHC Limit switch normally open held closed A1 Relay contact normally closed Fuse ENGINE START T-circuits connect Relay contact normally open HORN Horn button normally open Auxiliary lift pump KS1 PLATFORM FS1 BLK Emergency Stop button normally closed 6 - 10 Tilt sensor - P1 + Diode 6V Battery GROUND Key switch Foot switch (after Z34-3577 and Z34N-4260) PSI Pressure switch Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 6 • Schematics Hydraulic Symbols Legend N.O. COM N.C. Pressure switch Solenoid operated 3 position, 4 way, directional valve (D01 or D03) Hydraulic filter Normally closed poppet valve Check valve Normally open poppet valve Fixed displacement pump 0.045" (1.14 MM) Orifice with size 3000 PSI (207 bar) 3:1 Counterbalance valve Bi-directional motor Brake Solenoid operated dump valve Differential sensing valve Double acting cylinder M Pump prime mover (motor) 2800 psi (193 bar) Relief valve Solenoid operated proportional valve 25 PSI (1.7 bar) Filter with by-pass Part No. 36540 Solenoid operated 2 position, 3 way directional valve Genie Z-34/22 & Genie Z-34/22N 6 - 11 Section 6 • Schematics First Edition • Second Printing This page intentionally left blank. 6 - 12 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 Section 6 • Schematics First Edition • Third Printing Electrical Schematic (Z-34/22 before serial number 153) (Z-34/22N before serial number 304) A B C D E F G H I J K L M 1 WHT - FS RED/WHT-3 ORG-1 BLU/WHT-1 GRN OR BRN GROUND WHT - FS FS1 SET TO "N" - - + LVI / BCI OPTION UP PRIMARY BOOM DOWN UP DOWN + 1 ORG/BLK RED WHT GRN/WHT TB10 TB1 TB2 RED#1 RED/BLK#2 BLU#10 BLU/BLK#11 WHT/BLK#5 + - + - GRN/BLK 7 CR1 4 A2 A1 CR1 8 PR1 MOTOR + 2 RED-3 RED/BLK-3 + CR3 FB 6 S2 MOTOR S1 3 DISCHARGE LVI SET TO "A" TB11 TB4 WHT#4 BLK/RED#9 RED/BLK#28 REV PR2 WHT#23 FWD RED#R1 ORG/BLK#41 + PR4 PUMP 4 TS12 SECONDARY BOOM RIGHT B+ PUMP ORG UP DOWN PRIMARY BOOM BLU-3 BLU/BLK-3 TS11 TURNTABLE ROTATE TB9 TB23 24V - 5 A2 PR1 6 - 7 LEFT AP1 ( + ) 6 RESET CR3 TB5 TB28 F3 50A AP2 ( - ) WHT/BLK-3 1 B- WHT-3 5 TS10 WHT#23 PR3 3 WHT-2 + LS1 N.O.H.C. BLK/RED-3 RED/BLK-1 ORG/BLK#41 RED/WHT#3 RED#20 TB49 BLK#49 BLK#49 LS2 N.O.H.C. WHT#40 48V M- 7 8 3 RED CR3 TB40 - 5 GROUND TB3 4 UP F1 400A TS3 SECONDARY BOOM 15 A CIRCUIT BREAKER TB22 DOWN 3 PLATFORM TS2 RIGHT F2 100A CB1 TB20 P3 HORN TS1 LEFT AP2 ( + ) KS1 KEY SWITCH P1 EMERGENCY STOP BCI 4 TURNTABLE ROTATE F4 10A LIFT/DRIVE SELECT OPTION O/B BLK-2 A1 TILT ALARM TB42 TS18 O/R ORG-1 RED/WHT-3 ORG/RED-1 2 P2 EMERGENCY STOP BLK N A1 A2 S2 A3 H2 S1 (GND) AP1 ( - ) PRIMARY BOOM UP PRIMARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM DOWN DECENT ALARM OPTION TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT HORN COIL TILT LEVEL SENSOR FLASHING BEACON OPTION Part No. 36540 HORN DRIVE MASTER RELAY Genie Z-34/22 & Genie Z-34/22N DRIVE MOTOR SYSTEM PRIMARY PUMP MOTOR 6 - 13 AUXILIARY PUMP MOTOR 8 1 WHT RED/WHT-1 ORG - 1 BLU/WHT-1 GRN OR BRN (GROUND) WHT DRIVE ENABLE UP EXTEND DOWN PLATFORM LEVEL UP LEFT PLATFORM ROTATE RIGHT GRN-JIB DOWN JIB BOOM DE RETRACT ORG/BLK 7 GRN - GROUND RED#R2 BLK#7 ORG/BLK#15 ORG#14 BLU/WHT#48 WHT/RED#6 GRN/WHT#R2 WHT/RED#32 BLU#36 BLU/BLK#37 WHT#30 WHT/BLK#31 RED/WHT#29 RED RED#47 RED#16 6 BLK/WHT#8 A2 WHT#13 BLK#12 RED TB16 BLU/RED-3 ORG/BLK-1 RED#27 GRN/WHT HM TB13 TB12 GRN/WHT RED/WHT UP DOWN JIB BOOM RIGHT LEFT PLATFORM ROTATE UP DOWN PLATFORM LEVEL EXTEND PRIMARY BOOM RETRACT PS1 BLU/WHT-3 ORG/RED-3 GRN-2 RED/WHT-1 WHT/BLK-1 WHT-1 BLU/BLK-1 BLU-1 WHT/RED-1 RED-1 GRN/WHT-3 WHT/RED-3 BLU/WHT-1 GRN-1 GRN/BLK-1 GRN/BLK-3 GRN-3 ORG-3 ORG/BLK-3 BLK-3 BRAKE RELEASE 3 BLK/WHT-3 TB41 ORG/BLK RED WHT PRIMARY BOOM EXTEND PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT JIB BOOM UP JIB BOOM DOWN PROPORTIONAL FLOW CONTROL COIL LIFT PUMP RELAY COIL AUXILIARY PUMP RELAY COIL AUXILIARY CONTROL RELAY COIL PRESSURE SWITCH BRAKE RELEASE PROPORTIONAL STEER LEFT STEER RIGHT DRIVE REVERSE RELAY COIL DRIVE FORWARD RELAY COIL BRAKE RELEASE HALF STROKE TRAVEL ALARM (option) BRAKE RELEASE N.C. HOUR METER DRIVE ENABLE 8 PRIMARY BOOM RETRACT 6 - 14 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 TB31 TB29 LS3 PR4 2 PRIMARY BOOM CR2 TB30 TB36 TB46 TB37 TB27 TB47 PR3 GRN/BLK TB48 R A 5 TB6 TB43 TB18 TB14 TB7 TB44 TB17 TB15 TB8 TB19 TB19 GRN/WHT L - 4 J1 TB32 TS17 TS16 TS15 TS14 DP1 TS9 L1 R + + BOOM FUNCTION SPEED CONTROLLER AUX. PUMP TS13 WHT-JIB BLK-JIB ORG-JIB YEL-JIB X X BP1 A AUXILIARY PUMP TS7 TS6 TS5 TS4 RED GRN BLK/RED WHT DRIVE BOARD JOYSTICK BRAKE BOARD TS8 A B C D E F G H I J K L M N Section 6 • Schematics First Edition • Third Printing Electrical Schematic (Z-34/22 before serial number 153) (Z-34/22N before serial number 304) RED (GND) First Edition • Third Printing Section 6 • Schematics Electrical Schematic (Z-34/22 before serial number 153) (Z-34/22N before serial number 304) Section 6 • Schematics First Edition • Third Printing Electrical Schematic (Z-34/22 from serial number 153 to 1733) (Z-34/22N from serial number 304 to 2226) A B C P2 1 2 3 4 EMERGENCY STOP RED/BLK LOAD SENSE PCB 1 2 3 4 5 6 7 8 9 10 11 12 FS1 5 4 3 2 LVI RED-3 RED/BLK-3 BLU-3 BLU/BLK-3 WHT/BLK-3 WHT-3 WHT#23 ORG/BLK RED RED WHT UP DOWN PRIMARY BOOM UP DOWN SECONDARY BOOM - + TS12 ORG/BLK TB10 TB5 WHT#23 PR1 24V RIGHT LEFT LS1 N.O.H.C. B+ A2 TURNTABLE ROTATE 10 A BLK#49 CB2 1 B- TS11 TS10 FUNCTION ENABLE BLK#49 + M- WHT#23 WHT-2 BLK/RED-3 RED/BLK-1 TS19 TB49 3 SET TO "N” LVI / BCI OPTION TB52 PR3 1 DISCHARGE RED WHT#23 RED LS4 N.O.H.C. 3 ORG 5 BCI SET TO "A” WHT#52 + N O/B 6 RESET UP DOWN PRIMARY BOOM UP DOWN RIGHT LEFT SECONDARY BOOM 7 8 TB22 N.O.H.C. TB1 TB9 TB2 TB11 TB4 TB28 TB23 + - - + RED#1 RED/BLK#2 BLU#10 BLU/BLK#11 WHT/BLK#5 WHT#4 BLK/RED#9 + FB RED/BLK#28 RED#23 REV PR2 - RED#R1 FWD ORG/BLK#41 PR4 6 GRN/BLK CR1 A2 A1 PUMP + PUMP S2 MOTOR S1 BLK/RED#R1 PR1 MOTOR 7 A1 A2 S2 S1 H2 - AP1 ( - ) A3 TB50 PRIMARY BOOM UP PRIMARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM DOWN DECENT ALARM OPTION TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT HORN COIL TILT LEVEL SENSOR FLASHING BEACON (OPTION) Part No. 36540 HORN Genie Z-34/22 & Genie Z-34/22N BRN DRIVE MASTER RELAY DRIVE MOTOR SYSTEM PRIMARY LIFT PUMP MOTOR AUXILIARY LIFT PUMP MOTOR 6 - 15 HORN TS3 TS2 CR3 WHT#52 ORG/BLK#41 RED/WHT#3 + RED#20 F3 100A TS1 BLK#40 LS2 8 P3 4 GROUND 48V AP1 ( + ) A1 TILT ALARM BLK-22 PLATFORM EMERGENCY STOP TB20 AP2 ( - ) M WHT - FS RED/WHT-3 ORG-1 BLU/WHT-1 BRN WHT TURNTABLE ROTATE KEY SWITCH 10 A F1 400A BLK-2 KS1 P1 CB1 LIFT/DRIVE SELECT OPTION LOAD SENSE OPTION (SEE DETAIL AT LEFT) TB40 5 L O/R ORG-1 ORG/RED-1 RED/WHT-3 BLK TB3 - K TS18 P2 F4 10A 4 J EMERGENCY STOP AP2 ( + ) - I FS1 TB42 F2 100A H OL LOAD SENSE OPTION DETAIL RED/BLK 3 G BLK WHT-2 BRN F CR6 BLK/RED-3 CR6 3A E WHT -2 BLK WHT 2 RED/WHT 1 D 1 WHT - FS BLU/WHT-3 BLU/RED-3 ORG/RED-3 ORG/BLK-1 GRN/BLK-3 GRN-3 ORG-3 ORG/BLK RED/WHT AUXILARY UP EXTEND DOWN PLATFORM LEVEL UP LEFT PLATFORM ROTATE RIGHT DOWN JIB BOOM TB46 RETRACT TB13 WHT#13 BLK#12 RED#12 RED/WHT RED/WHT#29 WHT/BLK#31 WHT#30 BLU/BLK#37 BLU#36 WHT/RED#32 GRN/WHT RED#27 GRN/WHT RED RED RED#R2 BRN RED#16 TB16 7 GRN/WHT RED#47 ORG/BLK#47 GRN/WHT#R8 RED#20 WHT/RED#6 BRN GRN/BLK#44 BLK#7 ORG/BLK#15 ORG#14 LS3 BLK/WHT#8 PRIMARY BOOM EXTEND PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT JIB BOOM DOWN JIB BOOM UP PROPORTIONAL FLOW CONTROL COIL LIFT PUMP RELAY COIL LIFT PUMP CONTACTOR RELAY AUXILIARY PUMP RELAY COIL AUXILIARY CONTROL RELAY COIL PRESSURE SWITCH BRAKE RELEASE PROPORTIONAL STEER LEFT STEER RIGHT DRIVE REVERSE RELAY COIL DRIVE FORWARD RELAY COIL BRAKE RELEASE N.O. HALF STROKE TRAVEL ALARM BRAKE RELEASE N.C. HOUR METER DRIVE ENABLE 8 PRIMARY BOOM RETRACT 6 - 16 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 WHT/YEL GRN/BLK-1 GRN-1 WHT/RED-3 GRN/WHT-3 RED-1 WHT-1 ORG/BLK-3 TB29 TB37 WHT/GRN DRIVE ENABLE UP DOWN JIB BOOM BRN-JIB RIGHT LEFT PLATFORM ROTATE UP DOWN TB30 PRIMARY BOOM A2 HM PR4 PR3 3 RED/WHT-3 BLK-3 CR8 GRN/BLK#44 6 CR4 TB41 TB31 TB36 - PLATFORM LEVEL EXTEND TB19 PS1 CR2 5 TB27 TB47 PLATFORM LEVEL CUT-OUT OPTION N.C. N.C. TB44 WHT/BLK-1 BLK/WHT-3 BRAKE RELEASE TB12 TB6 TB43 TB18 N.O. ORG TB14 TB7 TB17 TB15 TB8 BLU-1 4 J1 WHT#23 ORG/BLK RED RED#20 WHT#23 DE RETRACT LS2 TB19 ORG/BLK TB32 TS17 BLK NO B PRIMARY BOOM YEL-JIB TS16 TS15 TS14 TS13 WHT/RED-1 BRN-2 BLU/BLK-1 WHT-JIB BLK-JIB ORG-JIB L1 DP1 BLK + NO STEER NC NO 1 NO RED/WHT NC RED R D X NC POWER 2 BP1 DRIVE/BRAKE CONTROL RED TS7 TS6 BOOM FUNCTION SPEED CONTROLLER 2 NO TS5 NC CR5 LCR RED WHT/RED WHT/BLK FWD/REV NC AUXILIARY PUMP RED TS9 TS8 WHT TS4 RED BRN BLK/RED Z-34/22: Control Relay CR5 was added after serial number 551 Z-34/22N: Control Relay CR5 was added after serial number 689 NOTE BLU/WHT-1 BRN WHT A B C D E F G H I J K L M N Section 6 • Schematics First Edition • Third Printing Electrical Schematic (Z-34/22 from serial number 153 to 1733) (Z-34/22N from serial number 304 to 2226) RED/WHT-3 ORG-1 BRN First Edition • Third Printing Section 6 • Schematics Electrical Schematic (Z-34/22 from serial number 153 to 1733) (Z-34/22N from serial number 304 to 2226) Section 6 • Schematics First Edition • Third Printing Electrical Schematic (Z-34/22 from serial number 1734 to 1834) (Z-34/22N from serial number 2227 to 2447) A B C RED/WHT LOAD SENSE OPTION 1 1 2 3 4 P2 LOAD SENSE PCB 3A E F G OL L4 FS1 RED/BLK BLK-FS 1 2 3 4 5 6 7 8 9 10 1112 WHT D CR17 I J K L M N LOAD SENSE OPTION (DETAIL AT LEFT) RED-FS P2 WHT-FS WHT FS1 EMERGENCY STOP ORG/RED-1 BLK-FS WHT-FS CR17 BRN H RED/WHT-3 RED/BLK RED KS1 P1 KEY SWITCH EMERGENCY STOP CB1 BLK-2 2 PLATFORM P3 HORN BLK #22 TB22 10 A + A1 - TILT ALARM GROUND TB31 RED WHT-1 WHT/BLK-1 TB32 WHT/RED-1 TB30 3 RED/WHT-1 TB29 TB40 F4 10A TB42 86 + - + - + ORG/RED RED/WHT 86 30 87 - + 85 FB F2 BLK BLK/RED PUMP ORG/RED #CR2 87 A1 WHT CR4 30 F1 MOTOR A1 85 LS1* MOTOR F1 RED/BLK #28 A2 RED A2 RED/WHT #23 WHT RED RED F2 F2 B+ 85 CR1 86 WHT-7 M- *Shown with boom extended 86 BLK/RED #CR4 5 B- BLK-7 CURTIS 1244 BLK 20 17 RED CR2 30 87 TB9 BLK-6 3 SEPEX MOTOR CONTROLLER F1 PR2 14 BLK + PR3 16 TB28 TB49 GRN 2 BLU/WHT #12 RED RED TS55 LS2 BRAKE/REL 11 BLK + - 10 POT. LOW 9 1 - OFF-LIMIT SPEED INPUT 24V AP1 INTERLOCK F3 100A 2-WIRE POT. RED REVERSE +48V INPUT BLK FORWARD DIODE RETURN BLK RED RED/WHT TB50 F2 100A RED/BLK-1 TB23 WHT-6 + - WHT-2 PR1 WHT-23A BLK/RED-3 BLK #22 LS4 WHT-8 ORG/RED #42 ORG/RED RED/BLK WHT/RED #32 ORG #40 BLU/WHT #12 RED/WHT #29 WHT/BLK #31 F1 500A AP2 7 WHT #30 ORG/RED RED #CB1 + - 5 6 CR5 85 48V BLK-8 AP2 (+) 4 TB3 PUMP H2 BRN BRN FUNCTION ENABLE 48V POWER RELAY CR2 48V POWER RELAY CR1 TILT SENSOR FLASHING BEACON (OPTION) HORN RELAY PRIMARY BOOM LIMIT SWITCH LS2 SECONDARY BOOM LIMIT SWITCH LS4 CONTROLLER FAULT INDICATOR LIGHT DRIVE CONTACTOR COIL DRIVE CONTACTOR Part No. 36540 TB52 HORN 48V BATTERY CHARGER Genie Z-34/22 & Genie Z-34/22N 10 A BRN BLK PRIMARY LIFT PUMP CB2 BLK EXTEND/RETRACT LIMIT SWITCH LS1 BLK AP1 ( - ) AUXILIARY LIFT PUMP 6 - 17 BLK BLK 8 BRN Jumper AUXILIARY PUMP BRN BLU/WHT-3 RED BLU-1 BLU/BLK-1 RED-1 GRN-1 GRN/BLK-1 GRN/BLK-3 GRN-3 BLU/RED-3 BLK-5 ORG/RED-3 ORG/RED RED/WHT WHT-5 RED/WHT #48 PS1 GRN/WHT-3 WHT/RED-3 RED-5 BRN-5 RED RED WHT #4 WHT/BLK #5 BLU/BLK #11 BLU #10 RED/BLK #2 RED #1 BLK/WHT # 8 BLK #7 + ORG/BLK #15 ORG #14 GRN/WHT WHT/RED #6 GRN/WHT RED/WHT #48 RED/WHT BLU #36 BLU/BLK #37 WHT/BLK RED #27 GRN/WHT GRN/WHT #19 JIB BOOM UP DOWN LEFT UP DOWN PLATFORM LEVEL EXTEND RETRACT PRIMARY BOOM UP DOWN PRIMARY BOOM UP SECONDARY BOOM DOWN RIGHT TB16 21 LS3* 14 RED/WHT TB48 WHT/BLK PLATFORM ROTATE RIGHT TB27 8 TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT DESCENT ALARM (OPTION) SECONDARY BOOM UP SECONDARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT PLATFORM LEVEL UP PLATFORM LEVEL DOWN PLATFROM LEVEL CUTOUT (CE OPTION) PROPORTIONAL FLOW CONTROL PR3 AUXILIARY LIFT PUMP CONTACTOR PR2 LIFT PUMP CONTACTOR CR20 LIFT PUMP CONTACTOR RELAY CR3 AUXILIARY LIFT PUMP CONTACTOR RELAY HOUR METER STEER RIGHT STEER LEFT PS1 BRAKE PRESSURE SWITCH BRAKE RELEASE N.O. VALVE BRAKE RELEASE N.C. VALVE TRAVEL ALARM (OPTION) DRIVE ENABLE LIMIT SWITCH TB52 5 AUXILIARY PUMP 30 6 - 18 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 RED O/B O/R ORG ORG/RED WHT UP JIB BOOM DOWN RIGHT PLATFROM ROTATE LEFT ORG-3 TB19 TURNTABLE ROTATE FUNCTION MANIFOLD GROUND PR2 TB36 TB13 GRN/WHT #19 LEFT rotated past either non-steer wheel 85 87A A2 A3 UP ORG/BLK-3 BLK-3 BLK/WHT-3 RED-3 RED/BLK-3 BLU-3 BLU/BLK-3 WHT/BLK-3 WHT-3 + PLATFORM LEVEL DOWN EXTEND PRIMARY BOOM RETRACT UP PRIMARY BOOM DOWN SECONDARY BOOM UP DOWN TURNTABLE ROTATE 7 86 87 PR3 *Shown with the boom 85 CR20 30 85 86 CR10B 87A 30 85 14 CR5 RED + HM 86 30 CR10A LS2 RED-6 13 TB12 4 BRN-2 BRN-JIB 6 86 CR3 30 WHT/RED #6 87A 87 ORG-6 (OPTION) 3 RED WHT-1 WHT/BLK-1 1 (remove for CE version) LVI / BCI OPTION 22 TB18 TB17 TB14 TB15 TB7 TB8 TB1 TB2 TB10 TB5 TB4 E 13 TB6 TB44 TB43 TB11 87 PLATFORM CONTROL BOX GROUND TS51 BLU/WHT #12 RED RED STEER 8 7 6 5 4 3 2 1 TB37 TS58 TS57 TS59 DP1 DRIVE ENABLE TS15 L R FWD J1 BRAKE RELEASE JIB MANIFOLD GROUND F BCI + RED BP1 SET TO "N” SET TO "A” BRN GRN BOOM FUNCTION BLK/RED SPEED CONTROLLER BLK-JIB WHT-JIB BLU-JIB ORG-JIB 4 4 TS63 TS61 TS60 TS62 6 CR19 WHT/RED-1 CR19 6 RED/WHT-1 ORG/RED LVI 2 REV RIGHT RED 4 5 3 DRIVE ENABLE LED DISCHARGE RESET CR19 DRIVE CONTROLLER BCI DRIVE 6 7 8 9 10 LIFT 1 2 3 4 5 TS1 TS8 TS7 TS9 TS13 TS11 TS10 TS12 BLK LEFT BRN WHT ORG/RED-1 A B C D E F G H I J K L M N Section 6 • Schematics First Edition • Third Printing Electrical Schematic (Z-34/22 from serial number 1734 to 1834) (Z-34/22N from serial number 2227 to 2447) WHT-FS BRN First Edition • Third Printing Section 6 • Schematics Electrical Schematic (Z-34/22 from serial number 1734 to 1834) (Z-34/22N from serial number 2227 to 2447) Section 6 • Schematics First Edition • Third Printing Electrical Schematic (Z-34/22 from serial number 1835 to 2060) (Z-34/22N from serial number 2448 to 2870) A B C D E P2 1 F FS1 G LOAD SENSE OPTION BLK-FS BLK #22 KS1 CB1 TB22 GND ORG/RED-1 + A1 ORG/RED-1 P1 10A N WHT RED P3 HORN WHT-2 2 M RED/WHT 8 LOAD SENSE PCB PLT L WHT-FS RED/WHT-3 RED + - K BLK-FS WHT NO J FS1 P2 BLK-2 NC C I LOAD SENSE OPTION (SEE DETAIL) WHT-FS RED/BLK H TILT ALARM RED RED RED TB30 WHT #30 TB31 WHT/BLK #31 WHT-1 WHT-1 WHT/BLK-1 WHT/BLK-1 3 RED/WHT #29 TB29 WHT/RED #32 TB32 ORG #40 TB40 RED/WHT-1 RED/WHT-1 WHT/RED-1 WHT/RED-1 BLK-8 TB3 ORG/RED #CR2 TB42 4 LS4 - + - + ORG/RED - + RED/WHT WHT NOTES: CR4 2 SWITCH SHOWN WITH BOOM EXTENDED 86 87 3 SWITCH SHOWN WITH BOOM ROATED PAST EITHER NON STEER WHEEL BLK 85 4 COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17. 5. CONTROLED DOCUMENT. ANY CHANGES MUST BE APPROVED BY FACTORY MUTUAL FOR EE CERTIFICATION. BRN - + F2 RIGHT MOTOR H2 TB52 BRN BLK BLK BLK 10A BLK (GND) BRN CB2 AP1 CR2 48V DC POWER RELAY CR1 48V DC POWER RELAY TILT SENSOR FLASHING BEACON OPTION Part No. 36540 HORN RELAY Genie Z-34/22 & Genie Z-34/22N HORN 48V DC BATTERY CHARGER PRIMARY LIFT PUMP AUXILIARY LIFT PUMP 6 - 19 87 1. ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED BLK/RED A1 BLK PUMP A1 GROUND BLK RED/BLK #28 F1 30 F1 LEFT MOTOR RED 30 FB PUMP 8 RED A2 RED/WHT #23 F2 BLK #22 WHT RED + RED A2 85 2 WHT-7 DRIVE CONTACTOR + F2 BLK/RED #CR4 BLK-7 B+ PR2 - - M- BLK-6 F1 PR3 LS1 13 CR1 85 14 DRIVE CONTROLLER STATUS LED (L3) B- 24V +24V 5 STATUS LED SEPEX CONTROLLER DRIVE CONTACTOR COIL-PR1 RED AP1 86 TB9 TB49 20 17 BLK F3 100A 86 LS2 BLK 3 CR2 87 22 GRN 14 TS55 FUNCTION ENABLE 30 TB28 21 BRAKE/REL 16 RED/BLK 2 11 POT. LOW INTERLOCK RED 10 2-WIRE POT. AP2 REVERSE BLK FORWARD +48V INPUT 9 1 6 DIODE RETURN BLK RED #CB1 + - OFF-LIMIT SPEED INPUT 5 + RED TB23 WHT-6 + F2 100A RED/WHT TB50 4 - RED/BLK-1 +48V 86 21 BLK/RED-3 PR1 CR5 WHT-8 RED 85 ORG/RED #42 F1 500A ORG/RED AP2 BLU/WHT #12 F4 10A ORG/RED RED 7 BLU/WHT #12 22 First Edition • Third Printing Section 6 • Schematics Electrical Schematic (Z-34/22 from serial number 1835 to 2060) (Z-34/22N from serial number 2448 to 2870) N M L K J I H G F E D C B A 1 LVI/BCI OPTION JP1 (REMOVE FOR CE VERSION) WHT ORG/RED-1 DP1 RED PLATFORM ROTATE TS7 JIB BOOM TS8 BLK DN UP RET UP DN EXT LIFT 7 2 REV 8 8 7 6 5 4 3 2 4 TS1 1 9 FWD R L 10 5 RESET 6 RED CR19 5 CR19 7 8 3 4 2 DRIVE UP DN R L 6 1 3 UP DN R L WHT PLATFORM LEVEL TS9 3 ORG PRIMARY BOOM TS13 O/R PRIMARY BOOM TS11 O/B SECONDARY BOOM TS10 5 ORG/RED WHT TURNTABLE ROTATE TS12 BCI 4 L.V.I. CR19 SET TO "B" TS15 STEER DISCHARGE AUX. PUMP SET TO "N" DRIVE ENABLE ORG/RED + BRN RED L1 BLU/WHT-3 WHT-1 WHT/BLK-1 BLU-JIB BLK-JIB + BRN GRN F BLK/RED RED GRN/BLK-1 JIB MANIFOLD GROUND BCI (OPTION) RED ROTARY OEM FLOW CONTROL BLU-1 BP1 BLU/BLK-1 WHT-JIB GRN-1 GRN-3 ORG-3 ORG/BLK-3 BLK-3 BLK/WHT-3 RED-3 RED/BLK-3 BLU-3 BLU/BLK-3 WHT/BLK-3 WHT-3 ORG-JIB GRN/BLK-3 WHT/RED-1 E + CONTROL BOX GROUND BRN-JIB J1 BRAKE RELEASE JACK BLU/WHT #12 4 TB12 AUX. PUMP TB5 RED/WHT TB48 LS3 21 3 13 22 RED-5 6 HM BRN-5 87 CR20 RED/WHT 30 + 14 RED/WHT #48 A3 ORG #14 ORG/BLK #15 + 8 85 87A BLU #36 2 87 RED 1 BLU/BLK #37 CR10 86 GRN/WHT 7 CR3 RED 6 30 TB6 WHT/RED #6 5 13 WHT/RED #6 RED-6 14 BLK #7 RED #1 BLK/WHT #8 LS2 WHT/BLK RED #27 RED/BLK #2 BLU #10 BLU/BLK #11 WHT/BLK #5 WHT #4 TB14 TB15 ORG-6 5 TB27 WHT-5 TB44 TB17 TB13 TB19 TB43 TB18 TB8 WHT/RED-3 TB1 GRN/WHT TB2 GRN/WHT #19 GRN/WHT #19 TB7 TB11 TB10 TB4 TB37 UP BRN-2 DN RED BLK-5 TS58 R L ORG/RED-3 TS57 UP DN ORG/RED TS59 EXT RET RED/WHT UP DN CR5 30 PS1 UP 87 TB36 RED TS63 TS61 DN R L JIB BOOM PLATFORM ROTATE RED-1 TS60 TS62 PLATFORM LEVEL PRIMARY BOOM PRIMARY BOOM GRN/WHT-3 SECONDARY BOOM TURNTABLE ROTATE BLU/RED-3 RED/WHT #48 TS51 RED RED 3 RED RED/WHT-1 TB16 85 86 + A2 (GND) FUNCTION MANIFOLD GROUND (GND) 7 TB52 BRN DRIVE ENABLE LED Genie Z-34/22 & Genie Z-34/22N DRIVE ENABLE LIMIT SWITCH TRAVEL ALARM (OPTION) BRAKE RELEASE N.C. VALVE BRAKE RELEASE N.O. VALVE STEER LEFT BRAKE RELEASE PRESSURE SWITCH STEER RIGHT HOUR METER CR3 AUXILIARY LIFT PUMP CONTACTOR RELAY CR20 LIFT PUMP CONTACTOR RELAY PR2 LIFT PUMP CONTACTOR PR3 AUXILIARY LIFT PUMP CONTACTOR PROPORTIONAL FLOW CONTROL PLATFORM LEVEL CUTOUT (CE OPTION) PLATFORM LEVEL DOWN PLATFORM LEVEL UP PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT PRIMARY BOOM UP PRIMARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM DOWN DESCENT ALARM (OPTION) TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT Part No. 36540 8 6 - 20 First Edition • Third Printing Section 6 • Schematics Electrical Schematic (Z-34/22 from serial number 1835 to 2060) (Z-34/22N from serial number 2448 to 2870) Section 6 • Schematics First Edition • Third Printing Electrical Schematic (Z-34/22 from serial number 2061 to 3577) (Z-34/22N from serial number 2871 to 4260) A B C D E F FS1 P2 1 BLK-FS G LOAD SENSE OPTION NO M WHT RED/WHT 8 N FS1 - BLK #22 GND ORG/RED-1 + A1 ORG/RED-1 RED P3 HORN TB22 CB1 L BLK-FS WHT-2 KS1 P1 10A K WHT-FS LOAD SENSE PCB 2 J RED/WHT-3 RED + P2 BLK-2 WHT C RED/BLK I LOAD SENSE OPTION (SEE DETAIL) WHT-FS NC PLT H TILT ALARM RED RED ORG/RED #CR20 RED TB30 WHT #30 TB31 WHT/BLK #31 WHT-1 WHT-1 WHT/BLK-1 WHT/BLK-1 3 RED/WHT #29 TB29 WHT/RED #32 TB32 TB40 ORG #40 RED/WHT-1 RED/WHT-1 WHT/RED-1 WHT/RED-1 BLK-8 TB3 ORG/RED #CR2 TB42 BLU/WHT #12 22 4 LS4 + - + - + WHT NOTES: 1. ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED 85 2 SWITCH SHOWN WITH BOOM EXTENDED FB 3 REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17. NOTE: DIODE INSTALLED AFTER SERIAL NUMBER 3819. BRN - + BRN 10A BRN (GND) (GND) BRN BLK (24V) PR2 PR3 TB52 CB2 AP1 CR2 48V DC POWER RELAY CR1 48V DC POWER RELAY TILT SENSOR FLASHING BEACON (OPTION) Part No. 36540 HORN RELAY HORN PR1, DRIVE CONTACTOR 48V DC BATTERY CHARGER PRIMARY LIFT PUMP AUXILIARY LIFT PUMP Genie Z-34/22 & Genie Z-34/22N ORG/RED RED/BLK #28 86 BRN BLK 87 H2 BLK BLK BLK BLK GROUND 85 RED 30 BLK RIGHT MOTOR RED F2 RED/WHT #23 A1 87 BLK LEFT MOTOR A1 CR4 30 F1 BLK/RED WHT RED RED + F1 PUMP A2 BLK #22 + - A2 86 2 WHT-7 PR2 - F2 BLK/RED #CR4 LS1 13 CR1 85 14 STATUS LED F2 B+ TB9 BLK-7 5 DRIVE CONTROLLER STATUS LED M- 86 BLK-6 20 17 DRIVE CONTACTOR COIL, PR1 F1 CR2 87 TB49 BPR3 BLK GRN 3 21 22 BRAKE/REL 14 RED/BLK 16 POT. LOW 2 FUNCTION ENABLE 30 TB28 LS2 SEPEX CONTROLLER PUMP 6 - 21 INTERLOCK F3 100A 24V +24V 8 11 2-WIRE POT. 10 REVERSE FORWARD RED AP1 7 9 BLK BLK RED DIODE RETURN +48V INPUT BLK RED #CB1 + 1 AP2 6 OFF-LIMIT SPEED INPUT 5 + L3 RED/WHT + F2 100A TS55 TB23 WHT-6 3 - RED RED/WHT TB50 +48V - BLK/RED-3 86 21 WHT-8 CR5 RED/BLK-1 ORG/RED #42 PR1 85 ORG/RED F1 500A 48V RED BLU/WHT #12 AP2 RED ORG/RED F4 10A First Edition • Third Printing Section 6 • Schematics Electrical Schematic (Z-34/22 from serial number 2061 to 3577) (Z-34/22N from serial number 2871 to 4260) N M L K J I H G F E D C B A 1 LVI/BCI OPTION JP1 (REMOVE FOR CE VERSION) WHT ORG/RED-1 RED PLATFORM ROTATE TS7 JIB BOOM TS8 BLK DP1 UP RET EXT UP DN L R LIFT UP DN 8 7 6 5 4 3 7 2 REV 8 4 9 FWD R L 10 5 RESET 5 CR19 6 CR19 RED 4 7 8 3 2 DRIVE AUX. PUMP 1 2 6 1 TS1 3 DN UP DN R L WHT PLATFROM LEVEL TS9 ORG PRIMARY BOOM TS13 3 O/R PRIMARY BOOM TS11 O/B SECONDARY BOOM TS10 ORG/RED WHT TURNTABLE ROTATE TS12 BCI 5 4 TS15 STEER DISCHARGE DRIVE ENABLE L.V.I. CR19 SET TO "B" SET TO "N" ORG/RED + BRN ORG/RED L1 WHT-1 WHT/BLK-1 3 RED RED/WHT-1 GRN-1 GRN/BLK-1 GRN/BLK-3 GRN-3 ORG-3 ORG/BLK-3 BLK-3 BLK/WHT-3 RED-3 RED/BLK-3 BLU-3 BLU/BLK-3 WHT/BLK-3 WHT-3 ROTARY OEM FLOW CONTROL JIB MANIFOLD GROUND CR5 BCI OPTION RED + BRN GRN F BLK/RED E J1 BRAKE RELEASE JACK CONTROL BOX GROUND BRN-JIB BLU/RED-3 BP1 BLU/WHT-3 WHT-JIB RED ORG-JIB WHT/RED-1 BLU-1 BLK-JIB BLU/BLK-1 BLU-JIB BLU/WHT #12 TB12 4 TB13 TS51 RED AUX. PUMP 87 CR5 TS63 TS58 TS57 TS59 PS1 GRN/WHT #19 TB19 TB5 TB2 TB1 TB7 TB8 TB18 TB17 TB27 TB44 TB43 ORG/RED (48V) TB10 TB11 RED/WHT #48 RED/WHT BLU #36 21 22 BRN-5 RED-5 8 GRN/WHT A3 + 7 *LS3 13 85 ORG #14 ORG/BLK #15 + 14 87A RED 2 87 RED 1 CR10 86 30 CR3 13 WHT/RED #6 6 TB6 RED-6 5 WHT/RED #6 BLU/BLK #37 BLK #7 BLK/WHT #8 RED #1 RED/BLK #2 BLU #10 BLU/BLK #11 WHT/BLK #5 WHT #4 ORG-6 14 LS2 RED #27 TB14 TB15 5 RED/WHT TB48 WHT/BLK GRN/WHT TB4 BRN-2 TB37 GRN/WHT #19 WHT-5 UP RED BLK-5 DN R ORG/RED-3 L UP ORG/RED DN RED/WHT EXT RET 30 RED/WHT #48 UP DN UP TB36 RED DN R GRN/WHT-3 TS61 TS60 L JIB BOOM PLATFORM ROTATE PLATFORM LEVEL WHT/RED-3 TS62 RED PRIMARY BOOM PRIMARY BOOM RED-1 SECONDARY BOOM TURNTABLE ROTATE 6 HM TB16 30 87 CR20 85 *Switch shown with boom rotated past either non-steer wheel. 86 + A2 (GND) (GND) TB52 BRN 7 BLK (24V) PR2 PR3 DRIVE ENABLE LED DRIVE ENABLE LIMIT SWITCH TRAVEL ALARM BRAKE RELEASE N.C. VALVE BRAKE RELEASE N.O. VALVE STEER LEFT BRAKE PRESSURE SWITCH STEER RIGHT HOUR METER CR3 AUXILIARY LIFT PUMP CONTACTOR RELAY CR20 LIFT PUMP CONTACTOR RELAY PR2 PRIMARY LIFT PUMP PR3 AUXILIARY LIFT PUMP PROPORTIONAL FLOW CONTROL JIB BOOM DOWN JIB BOOM UP PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT PLATFORM LEVEL CUTOUT (CE OPTION) PLATFORM LEVEL DOWN PLATFORM LEVEL UP PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND PRIMARY BOOM UP PRIMARY BOOM DOWN SECONDARY BOOM DOWN SECONDARY BOOM UP DESCENT ALARM (OPTION) TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT FUNCTION MANIFOLD GROUND 8 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 6 - 22 First Edition • First Printing Section 6 • Schematics Electrical Schematic (Z-34/22 from serial number 2061 to 3577) (Z-34/22N from serial number 2871 to 4260) First Edition • Third Printing Section 6 • Schematics Electrical Schematic (Z-34/22 from serial number 3578 to 4799) (Z-34/22N from serial number 4261 to 5619) A B C D E F G H I J K L M N BL/WH-1 TB134 FS1 P2 1 BLK-FS BLK-2 1 RED #134B WHT-FS 3 4 ORG/RED-1 4 U33 TB22 BLK #22 12 + 8 P3 HORN CB1 H6 2 GND RED WHT-2 PLT H1 L4 D39 BLU/RED-1 5 4 4 L48 D40 L45 RED TILT ALARM ORG/RED-1 LS18 KS1 P1 6 4 7 RED/WHT-3 6 10A WHT 5 ORG/RED ORG/RED #CR20 TB30 WHT #30 WHT-1 TB31 WHT/BLK #31 WHT-1 WHT/BLK-1 WHT/BLK-1 BLU/WHT #12 3 RED/WHT #29 TB29 RED/WHT-1 RED/WHT-1 WHT/RED #32 TB32 WHT/RED-1 WHT/RED-1 ORG #40 TB40 BLK-8 TB3 ORG/RED #CR2 TB42 BLU/WHT #12 22 LS4 + - + + CR4 87 86 RIGHT MOTOR FB1 BLK F2 85 BLK/RED A1 30 F1 BLK PUMP A1 85 C RED WHT RED RED + PUMP F1 CR1 86 WHT WHT-7 A 87 LEFT MOTOR 86 85 2 CR2 87 13 30 A2 A2 RED ORG/RED BLK #22 RED/BLK #28 LS1 RED/WHT #23 BLK/RED #CR4 BLK-7 DRIVE CONTROLLER STAUS LED DRIVE CONTACTOR COIL F2 B+ PR2 F2 FUNCTION ENABLE RED/WHT BLK-6 30 14 STATUS LED 5 B- M- RED/WHT WHT-6 20 17 F1 TB28 TB9 TB49 24V PR3 BLK GRN 3 TS55 LS2 BRAKE/REL 14 RED/BLK POT. LOW 2-WIRE POT. REVERSE INTERLOCK FORWARD +48V INPUT 16 21 + - - RED - 2 11 TB23 22 CURTIS 1244 SEPEX CONTROLLER F3 100A AP1 6 10 + L37 BLK AP2 +24V DIODE RETURN BLK RED #CB1 + 9 1 BLK OFF-LIMIT SPEED INPUT DRIVE CONTACTOR + - 5 F2 100A RED/BLK-1 TB50 PR1 3 - BLK/RED-3 86 RED 21 WHT-8 +48V CR5 PR1 AP2 ORG/RED #42 4 F1 500A RED 85 ORG/RED RED ORG/RED F4 10A B H2 BRN + BRN - GROUND BLK BLK BLK BLK 7 BLK (GND) 10A BRN BRN TB52 (GND) CB2 AP1 BRN BLK (24V) PR2 48V POWER RELAY (CR2) 24V POWER RELAY (CR1) TILT SENSOR FLASHING BEACON (OPTION) HORN RELAY HORN EXTEND/RETRACT LIMIT SWITCH LS1 PRIMARY UP/DOWN LIMIT SWITCH LS2 SECONDARY UP/DOWN LIMIT SWITCH LS4 48V BATTERY CHARGER 6 - 23 PRIMARY LIFT PUMP AUXILIARY LIFT PUMP 8 PR3 NOTES: 1. ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED 5 ADD D40 ONLY IF UNIT HAS L4 & L48. 2 6 ANSI/CSA 7 LIMIT SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL SWITCH SHOWN WITH BOOM EXTENDED 3 REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17. 4 CE & PLATFORM LOAD SENSE OPTION. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 ES34DCL First Edition • Third Printing Section 6 • Schematics Electrical Schematic (Z-34/22 from serial number 3578 to 4799) (Z-34/22N from serial number 4261 to 5619) N M L K J I H G F E D C B A 1 LVI/BCI OPTION JP1 (REMOVE FOR CE VERSION) WHT ORG/RED-1 RED JIB BOOM TS8 BLK DOWN UP LEFT RIGHT DOWN UP EXT RET UP DOWN UP DOWN LEFT RIGHT 8 7 6 5 4 RESET 6 CR19 4 8 CR19 AUX. PUMP 1 3 REV 4 FWD 7 8 DRIVE 9 R 5 L DISCHARGE STEER SET TO "N" ORG/RED SET TO "B" 3 2 6 LIFT 2 10 TS15 DRIVE ENABLE 2 L.V.I. 7 CR19 5 3 DP1 1 TS1 WHT PLATFORM ROTATE TS7 ORG/RED PLATFORM LEVEL TS9 3 ORG PRIMARY BOOM TS13 O/R PRIMARY BOOM TS11 O/B SECONDARY BOOM TS10 WHT TURNTABLE ROTATE TS12 BCI 5 4 + BRN L1 DRIVE ENABLE LED ORG/RED WHT-1 WHT/BLK-1 RED/WHT-1 3 RED BLU-JIB BLK-JIB F BLU/RED-3 BRN BLK/RED BLU/WHT-3 + GRN ORG/RED-3 RED BLU-1 GRN/BLK-1 GRN-3 ORG-3 ORG/BLK-3 BLK-3 BLK/WHT-3 RED-3 RED/BLK-3 BLU-3 BLU/BLK-3 ROTARY OEM FLOW CONTROL BLU/BLK-1 WHT-JIB BP1 GRN-1 ORG-JIB WHT/BLK-3 WHT-3 GRN/BLK-3 WHT/RED-1 E BCI JIB MANIFOLD GROUND CONTROL BOX GROUND BRN-JIB BLU/WHT #12 TB12 4 TS51 RED AUX. PUMP 87 CR5 TS59 TS58 TS57 RED/WHT #48 RED/WHT BLU #36 BLU/BLK #37 LS3 + HM 6 ORG #14 TB16 30 CR20 87 85 86 + H3 FUNCTION MANIFOLD GROUND (GND) BRN-5 8 85 7 22 13 RED-5 2 ORG/BLK #15 H4 87A RED 1 + WHT/BLK CR10 87 GRN/WHT 7 RED 6 86 30 5 21 14 CR3 WHT/RED #6 5 WHT/RED #6 13 RED-6 14 TB6 RED/WHT TB48 RED #27 BLK #7 BLK/WHT #8 RED #1 RED/BLK #2 BLU #10 BLU/BLK #11 WHT/BLK #5 WHT #4 TB15 ORG-6 BRN-2 TB43 WHT-5 TB44 TB14 LS2 BLK-5 TB17 TB2 TB13 TB27 ORG/RED (48V) TB18 ORG/RED RED/WHT TB19 TB8 GRN/WHT TB11 TB1 GRN/WHT #19 GRN/WHT #19 RED TB7 TB10 TB4 30 TB37 PS1 DN UP R L UP DN EXT RET UP TB5 TB36 JIB BOOM RED TS63 PLATFORM ROTATE PLATFORM LEVEL RED-1 TS61 DN L R UP DN RED PRIMARY BOOM GRN/WHT-3 TS60 TS62 PRIMARY BOOM WHT/RED-3 SECONDARY BOOM TURNTABLE ROTATE (GND) TB52 BRN 7 BLK (24V) PR2 PR3 DRIVE ENABLE LED DRIVE ENABLE LIMIT SWITCH TRAVEL ALARM BRAKE RELEASE N.C. VALVE BRAKE RELEASE N.O. VALVE STEER LEFT BRAKE PRESSURE SWITCH STEER RIGHT HOUR METER CR3 AUXILIARY LIFT PUMP RELAY CR20 PRIMARY LIFT PUMP RELAY PR2 PRIMARY LIFT PUMP CONTACTOR PR3 AUXILIARY LIFT PUMP CONTACTOR PROPORTIONAL FLOW CONTROL JIB BOOM UP JIB BOOM DOWN PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT PLATFORM LEVEL CUTOUT (CE OPTION) PLATFORM LEVEL UP PLATFORM LEVEL DOWN PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT PRIMARY BOOM DOWN PRIMARY BOOM UP SECONDARY BOOM UP SECONDARY BOOM DOWN DESCENT ALARM (OPTION) TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT 8 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 6 - 24 First Edition • Third Printing Section 6 • Schematics Electrical Schematic (Z-34/22 from serial number 3578 to 4799) (Z-34/22N from serial number 4261 to 5619) Section 6 • Schematics First Edition • Third Printing Electrical Schematic (Z-34/22 after serial number 4799) (Z-34/22N after serial number 5619) A B C D E F G H I J K L M N C29JSH RD/WH C32JSL WH/RD 1 C31REV WH/BK C30FWD WH TB134 FS1 P2 BK-(FS) C9P-1 BK C7P-1 RD-(FS) C9P-3 WH-(FS) C9P-2 P24BAT WH P26BAT RD R42BAT OR/RD C132PLI BL/WH P1 P182BAT RD C1B-12 10 A TB22 KS1 RD PLATFORM P22BAT BK 2 RD C1P-12 + TILT ALARM H1 P3 HORN L48 CB2 C2B-4 86 A 13 14 H2 LS1 (EXT) 2 FB 33W BRN - BK PR2 B BK 2 GA C48-3 10A BRN BRN BRN AC POWER 7 + PR3 BK 21 22 + C WH LS2 (PRI) CHARGER 33W RD RIGHT MOTOR 85 R19LPE GR/WH A1 F1 C10-1 BK-7 A1 F2 C10-2 WH-7 A2 - - 30 OR/RD - C3B-3 85 87 CR20 C11-4 WH-6 F1 A2 87 CR1 RD/WH 87 CR4 C11-3 BK-6 - WH + F2 + GROUND RD 86 87 LEFT MOTOR RD/BK 30 B- F2 RD C49-1 R27AUX RD 22 PR2 PUMP C49-11 C19LPE GR/WH 5 20 17 2 3 16 14 11 10 9 1 PR3 B+ 30 85 30 86 87 87a 86 85 J1-WH M- 30 CR3 LS4 21 (SEC) - + - R42BAT OR/RD C1B-2 C9HRN BK/RD BK P22LS BK J2-BK C52-1 BK-8 C52-2 WH-8 C49-7 C178CSL BK C49-2 C48BRK RD/BK + C3BAT RD/WH C7B-2 CR2 U6A MOTOR CONTROLLER F1 C19LPE GR/WH TB42 P42BAT OR/RD C48-2 CONTROLLER STATUS LED L3 CR5 C182PWR GR INTERLOCK POT. HI POT. LOW REVERSE FORWARD DIODE RETURN +48V INPUT F3 100A C19LPE GR/WH OR/RD OR/RD 86 OFF-LIMT SPD INP BL/WH RD 20 - + + C2P-4 C28TTA RD/BK CR5 C12DRE BL/WH OR/RD C49-9 C49-8 RD/WH WH/RD WH WH/BK - + + C3P-3 P23BAT WH TB134 C134PWR RD R42BAT OR/RD 85 F2 100 A PUMP + C7P-2 C3B-9 C1P-2 C9HRN BK/RD C49-3 RD TB40 C40LS C3P-9 C49-6 GR/BK C2B-1 C1B-3 C49-5 8 C133PLA BL/RD C1B-6 C49-4 C2P-1 C29JSH RD/WH C1B-5 C7B-1 C32JSL WH/RD C1B-4 RD C1P-3 C31REV WH/BK 7 5 PR1 24 V RIGHT BOX P22BAT BK C1P-6 C30FWD WH R42BAT OR/RD 48V F4 500A AP2 6 6 P42BAT OR/RD PR1 +24 V 5 12 C49-10 AP2 AP1 3 U33 P42BAT OR/RD +48 V 5 1 4 C12FTS F5 10A LEFT BOX C1P-5 C48-1 P182BAT RD 4 C1P-4 3 GROUND TB52 GND BR CB3 48V POWER RELAY CR2 Part No. 36540 48V POWER RELAY CR1 Genie Z-34/22 & Genie Z-34/22N FLASHING BEACON OPTION 6 - 25 TILT SENSOR 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. BASE CONTROL BOX GROUND SWITCH SHOWN WITH BOOM EXTENDED. SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. AUXILIARY LIFT PUMP PR3 2 3 PRIMARY LIFT PUMP CONTACTOR RELAY 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. PRIMARY LIFT PUMP PR2 HORN RELAY HORN LS1-EXT/RET LS2-PRI. UP/DWN LS4-SEC. UP/DWN CHASSIS GROUND BRAKE RELEASE RELAY CR5 PR1 DRIVE CONTACTOR PRIMARY LIFT PUMP AUXILIARY LIFT PUMP NOTES: 8 CR3 P182BAT BK AP1 First Edition • Third Printing Section 6 • Schematics Electrical Schematic (Z-34/22 after serial number 4799) (Z-34/22N after serial number 5619) N M L K J I H G F E D C C29JSH RD/WH B A C29JSH RD/WH C32JSL WH/RD C32JSL WH/RD C31REV WH/BK C31REV WH/BK C30FWD WH C30FWD WH 1 LVI/BCI OPTION P24BAT WH P24BAT WH R42BAT OR/RD DP1 JIB BOOM TS8 UP DOWN RIGHT LEFT UP DOWN EXTEND RETRACT UP DOWN UP DOWN RIGHT LEFT 8 6 CR19 7 6 5 3 3 20K FWD 1 2 AUXILIARY PUMP TS1 DISCHARGE L.V.I. 8 SET TO "B" 1 L1 7 8 30 UP DOWN RIGHT LEFT UP DOWN PS1 EXTEND RETRACT UP DOWN UP DOWN RIGHT LEFT C19LPE TB11 TB10 TB2 TB7 TB8 TB1 GR/WH TB19 TB48 GR/WH RD TB19 TB5 87 TB36 C27AUX RD TB27 GR/WH TB4 CR5 TB37 TB14 TB15 R48BRK 86 TB6 CR3 85 TB16 LS3 21 C7B-3 BATGND BRN (GND) C8-2 A2 A3 BRN-5 OR OR/BK OR + DRIVE ENABLE LIMIT SWITCH 22 C8-1 + HM _ 5 3 14 86 85 87 13 RD-5 85 CR10B RD/WH CR10A 86 87 30 13 WH/RD 30 RD-6 R48BRK RD/WH CE RD C11-1 BL 14 BL/BK BR-6 WH/BK BK BK/WH RD RD/BK BL BL/BK WH/BK WH CE OG/BK C11-2 LS2 + WH-5 TS58 C7P-3 BATGND BRN TS57 C8-4 TS59 BRN TS63 C13DEL BL/RD TS61 C4B-1 TS60 C13DEL BL/RD TS62 BK-5 JIB BOOM C8-3 PLATFORM ROTATE 4 C12FTS BL/WH PLATFORM LEVEL OR/RD PRIMARY BOOM RD PRIMARY BOOM C19LPE GR/WH SECONDARY BOOM C16DE OR/RD RD TURNTABLE ROTATE C4B-4 FUNCTION ENABLE C3B-12 TS55 3 TB12 AUXILIARY PUMP TS51 RD C16DE OR/RD C1B-10 C19LPE GR/WH C12FTS BL/WH C36SCC BL C4B-7 C1B-11 C19LPE GR/WH C3B-6 C2B-5 C2B-6 C4B-5 C4B-6 C4B-2 C4B-3 C3B-7 C3B-8 C3B-1 C3B-2 C3B-10 C3B-11 C3B-4 C3B-5 C6MFV WH/RD BCI OPTION C37SCW BL/BK BCI C1B-1 F E C27AUX RD C4P-7 C43JU GR C44JD GR/BK C44JD WH C43JU BK C18PRL OR C17PRR BL C17PRL GR C18PRR GR/BK C14PLU OR C15PLD OR/BK C7PBE BK C8PBR BK/WH C1PBU RD C2PBD RD/BK C11SBD BL/BK C10SBU BL C5TRR WH/BK C4TRL WH C3P-6 + C4P-1 BRN C4P-4 9 10 CE OPTION: REMOVE JUMPER AND ADD RELAY C3P-12 GR BK/RD 2 4 5 C1P-10 RD DRIVE ENABLE TS15 2 3 C1P-11 L R STEER C1P-1 C2P-5 C2P-6 C47-3 C47-4 C47-1 C47-2 C4P-6 C4P-5 C4P-2 C4P-3 C3P-7 C3P-8 C3P-1 C3P-2 C3P-10 C3P-11 C3P-5 C3P-4 JIB MANIFOLD CR5 C12DRE BL/WH ROTARY OEM FLOW CONTROL 1 6 LIFT SET TO "N" DRIVE BP1 RD 4 RESET CR19 5 CR19 BCI 5 REV 7 2 4 RD PLATFORM ROTATE TS7 RD-AUX PLATFORM LEVEL TS9 OR/RD PRIMARY BOOM OR/RD TS13 ORG PRIMARY BOOM TS11 OR/BK SECONDARY BOOM TS10 WH TURNTABLE ROTATE TS12 6 7 TB52 CR3 TRAVEL ALARM BRAKE RELEASE NC COIL BRAKE RELEASE NO COIL Part No. 36540 BRAKE RELEASE PRESSURE SWITCH SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. STEER RIGHT 3 STEER LEFT SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES. HOUR METER ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 5 AUXILIARY CONTROL RELAY 4. SWITCH SHOWN WITH BOOM EXTENDED. PROPORTIONAL CONTROL VALVE ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. PLATFORM ROTATE RIGHT/ JIB BOOM UP 1. PLATFORM ROTATE LEFT/ JIB BOOM DOWN PLATFORM LEVEL CUT-OUT OPTION PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL BOOM RETRACT BOOM EXTEND PRIMARY BOOM UP PRIMARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM DOWN DESCENT ALARM OPTION TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT NOTES: 2 Genie Z-34/22 & Genie Z-34/22N 8 6 - 26 First Edition • Third Printing Section 6 • Schematics Electrical Schematic (Z-34/22 after serial number 4799) (Z-34/22N after serial number 5619) Section 6 • Schematics First Edition • Third Printing Electrical Schematic - CE Models (Z-34/22 after serial number 4799) (Z-34/22N after serial number 5619) A B C D E F G H I J K L M N C29JSH RD/WH C32JSL WH/RD 1 C31REV WH/BK C30FWD WH TB134 FS1 P2 BK-(FS) C9P-1 BK C7P-1 RD-(FS) C9P-3 WH-(FS) C9P-2 P24BAT WH P26BAT RD R42BAT OR/RD P1 P182BAT RD C1B-12 10 A TB22 KS1 LS18 RD PLATFORM P22BAT BK 2 RD C1P-12 C132PLI BL/WH + TILT ALARM H1 L4 P3 HORN L48 5 D39 6 D40 CB2 13 14 LS1 (EXT) 2 FB PR3 33W BRN PR2 B - BK 2 GA C48-3 10A BRN BRN BRN AC POWER 7 + BK 21 22 H2 C WH LS2 (PRI) 33W RD RIGHT MOTOR CHARGER + BK - A 85 R19LPE GR/WH A1 F1 C10-1 BK-7 A1 F2 C10-2 WH-7 F1 A2 C11-4 WH-6 F2 A2 - GROUND 86 CR20 C11-3 BK-6 - WH + PUMP 30 B- - + - 85 OR/RD + C2B-4 87 87 RD/WH 86 87 + PUMP RD 30 PR2 LEFT MOTOR 87 CR1 C49-1 R27AUX RD 22 CR4 F2 30 85 85 C49-11 C19LPE GR/WH 20 B+ 86 30 86 87 87a LS4 21 (SEC) 5 17 2 3 16 14 11 10 9 1 M- F1 30 CR3 RD/BK C9HRN BK/RD BK P22LS BK J2-BK C52-1 BK-8 C52-2 WH-8 C49-7 C178CSL BK C49-2 C48BRK RD/BK C182PWR GR + R42BAT OR/RD C3B-3 CR2 J1-WH PR3 RD P42BAT OR/RD C48-2 CONTROLLER STATUS LED L3 85 CR5 PR1 INTERLOCK POT. HI POT. LOW REVERSE FORWARD +48V INPUT DIODE RETURN OFF-LIMT SPD INP BL/WH RD 20 - + F3 100A C19LPE GR/WH TB42 OR/RD OR/RD OR/RD C49-9 C49-8 RD/WH WH/RD WH/BK WH 86 - + + C2P-4 C3BAT RD/WH C1B-2 C12DRE BL/WH R42ABT OR/RD U6A MOTOR CONTROLLER 24 V + C3P-3 C7B-2 C49-3 C28TTA RD/BK C49-6 P23BAT WH C1B-3 C49-5 C7P-2 C1B-6 C49-4 C1P-2 C1B-5 R42BAT OR/RD F4 500A AP2 RIGHT BOX C3B-9 C1B-4 C48-1 P182BAT RD 48V F2 100 A +24 V CR5 C19LPE GR/WH P42BAT OR/RD PR1 AP1 TB134 C134PWR RD C49-10 +48 V 6 RD TB40 C40LS P42BAT OR/RD AP2 5 GR/BK C12FTS F5 10A LEFT BOX L45 C9HRN BK/RD 8 C3P-9 12 C2B-1 C29JSH RD/WH 7 5 C133PLA BL/RD C32JSL WH/RD 6 C2P-1 C1P-3 C31REV WH/BK 5 U33 H6 4 C7B-1 C1P-6 C30FWD WH 3 4 RD C1P-5 1 P22BAT BK C1P-4 3 GROUND TB52 GND BR CB3 48V POWER RELAY CR2 48V POWER RELAY CR1 FLASHING BEACON OPTION TILT SENSOR Part No. 36540 BASE CONTROL BOX GROUND Genie Z-34/22 & Genie Z-34/22N AUXILIARY LIFT PUMP PR3 6 - 27 PRIMARY LIFT PUMP CONTACTOR RELAY 4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. PRIMARY LIFT PUMP PR2 ADD D40 ONLY IF UNIT HAS L4 AND L48. HORN RELAY SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. CE & PLATFORM LOAD SENSE OPT. 6 HORN 3 5 LS1-EXT/RET SWITCH SHOWN WITH BOOM EXTENDED. LS2-PRI. UP/DWN LS4-SEC. UP/DWN 2 CHASSIS GROUND NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. BRAKE RELEASE RELAY CR5 PR1 DRIVE CONTACTOR PRIMARY LIFT PUMP AUXILIARY LIFT PUMP 8 CR3 P182BAT BK AP1 First Edition • Third Printing Section 6 • Schematics Electrical Schematic - CE Models (Z-34/22 after serial number 4799) (Z-34/22N after serial number 5619) N M L K J I H G F E D C C29JSH RD/WH B A C29JSH RD/WH C32JSL WH/RD C32JSL WH/RD C31REV WH/BK C31REV WH/BK C30FWD WH C30FWD WH 1 LVI/BCI OPTION P24BAT WH P24BAT WH R42BAT OR/RD DP1 JIB BOOM TS8 UP DOWN RIGHT LEFT UP DOWN EXTEND RETRACT UP DOWN UP DOWN RIGHT LEFT 8 6 CR19 7 6 5 3 3 20K FWD 1 2 AUXILIARY PUMP TS1 DISCHARGE L.V.I. 8 SET TO "B" 1 L1 7 8 UP DOWN RIGHT LEFT UP DOWN PS1 EXTEND RETRACT UP DOWN UP DOWN RIGHT LEFT C19LPE GR/WH TB5 TB11 TB10 TB2 TB7 TB8 TB1 GR/WH TB19 TB48 GR/WH RD TB19 TB4 CR5 87 TB36 C27AUX RD TB27 TB14 TB15 R48BRK 86 TB6 CR3 85 TB16 3 14 86 85 OR OR/BK OR + A2 A3 (GND) C7B-3 BATGND BRN + HM _ DRIVE ENABLE LIMIT SWITCH 22 C8-2 CR10B 87 5 21 BRN-5 30 LS3 C8-1 85 13 RD-5 87 RD/WH CR10A 86 13 WH/RD 30 R48BRK RD/WH LS2 RD-6 BL 14 BL/BK BR-6 WH/BK BK BK/WH RD RD/BK BL BL/BK WH/BK WH CE OG/BK C11-2 CE RD C11-1 + WH-5 30 TB37 C7P-3 BATGND BRN TS58 C8-4 TS57 BRN TS59 C13DEL BL/RD TS63 C4B-1 TS61 C13DEL BL/RD TS60 C4P-1 TS62 BK-5 JIB BOOM C8-3 PLATFORM ROTATE 4 C12FTS BL/WH PLATFORM LEVEL OR/RD PRIMARY BOOM RD PRIMARY BOOM C19LPE GR/WH SECONDARY BOOM C16DE OR/RD RD TURNTABLE ROTATE C4B-4 FUNCTION ENABLE C3B-12 C4B-7 TS55 3 TB12 AUXILIARY PUMP TS51 RD C16DE OR/RD C19LPE GR/WH C3B-6 C19LPE GR/WH C12FTS BL/WH C1B-10 C6MFV WH/RD BCI OPTION C4P-4 C36SCC BL BCI CE OPTION: REMOVE JUMPER AND ADD RELAY C3P-12 C1P-10 C1B-11 F E C2B-5 C2B-6 C4B-5 C4B-6 C4B-2 C4B-3 C3B-7 C3B-8 C3B-1 C3B-2 C3B-10 C3B-11 C3B-4 C3B-5 C37SCW BL/BK C4P-7 C3P-6 C43JU GR C44JD GR/BK C44JD WH C43JU BK C18PRL OR C17PRR BL C17PRL GR C18PRR GR/BK C14PLU OR C15PLD OR/BK C7PBE BK C8PBR BK/WH C1PBU RD C2PBD RD/BK C11SBD BL/BK C10SBU BL C5TRR WH/BK C4TRL WH C1P-11 9 10 BRN + 2 4 5 C1B-1 GR BK/RD DRIVE ENABLE TS15 2 3 C27AUX RD L R STEER C1P-1 C2P-5 C2P-6 C47-3 C47-4 C47-1 C47-2 C4P-6 C4P-5 C4P-2 C4P-3 C3P-7 C3P-8 C3P-1 C3P-2 C3P-10 C3P-11 C3P-5 C3P-4 JIB MANIFOLD CR5 C12DRE BL/WH ROTARY OEM FLOW CONTROL RD 1 6 LIFT SET TO "N" DRIVE BP1 RD 4 RESET CR19 5 CR19 BCI 5 REV 7 2 4 RD PLATFORM ROTATE TS7 RD-AUX PLATFORM LEVEL TS9 OR/RD PRIMARY BOOM OR/RD TS13 ORG PRIMARY BOOM TS11 OR/BK SECONDARY BOOM TS10 WH TURNTABLE ROTATE TS12 6 7 TB52 CR3 TRAVEL ALARM BRAKE RELEASE NC COIL BRAKE RELEASE NO COIL Part No. 36540 BRAKE RELEASE PRESSURE SWITCH SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL. STEER RIGHT 3 STEER LEFT SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES. HOUR METER ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED. 5 AUXILIARY CONTROL RELAY 4. SWITCH SHOWN WITH BOOM EXTENDED. PROPORTIONAL CONTROL VALVE ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED. PLATFORM ROTATE RIGHT/ JIB BOOM UP 1. 2 PLATFORM ROTATE LEFT/ JIB BOOM DOWN PLATFORM LEVEL CUT-OUT OPTION PLATFORM LEVEL UP COIL PLATFORM LEVEL DOWN COIL BOOM RETRACT BOOM EXTEND PRIMARY BOOM UP PRIMARY BOOM DOWN SECONDARY BOOM UP SECONDARY BOOM DOWN DESCENT ALARM OPTION TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT NOTES: Genie Z-34/22 & Genie Z-34/22N 8 6 - 28 First Edition • Third Printing Section 6 • Schematics Electrical Schematic - CE Models (Z-34/22 after serial number 4799) (Z-34/22N after serial number 5619) Section 6 • Schematics First Edition • Third Printing Ground Control Panel Legend (Z-34/22 before serial number 153) (Z-34/22N before serial number 304) A B C D E F G H I 1 A3 A2 3 2 4 7 1 3 5 2 4 6 M N RED-TB27D 7 8 6 GRN/YEL-GROUND 8 RED-PR4 GRN/WHT-PR3 CR1 2 1 3 4 P1 7 1 2 2 5 3 5 4 6 BLK/RED-TB9D 7 8 6 8 BLK-TILT AL. GRN/YEL-TB51 BLK-LS1 BLU/WHT-MH RED-B.R.V. GRN/YEL-GROUND BLK-HORN NC RED-SP HM WHT-HORN NC 3 LIMIT SWITCH WIRING LS2 LS1 TS17 BRAKE 4 EXTEND/RETRACT LIMIT SWITCH PRIMARY BOOM LIMIT SWITCH KS1 N.O. RELEASE NO NO BLK#49-TB49D N.O. N.C. 5 TS15 WHT#40-TB40D N.C. BLK#49-TB49C WHT#23-TB23D LS3 LS4 DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM LIMIT SWITCH OG/RD-POW. ORG/BLK-PR1 WHT-LS2 BLU/BLK-S.V. BLU-STEER V. WT/RD-BK.F.C. WT/BK-PR2 WHT-PR2 RD/WT-B.V. WHT-T. AL. RED-CR2 WHT-LS1 N.O. BLK#12-TB12A N.O. N.C. GRN-GROUND N.C. BLK#40-TB40B GRN/WHT-CR2 WHT#52-TB52B Note: LS4 added after serial number 950 TS14 ORG/BLK-4 ORG-4 TS12 CB1 LABEL TS16 TS11 GRN/YEL-2 GR/YL-PUMP BLK-LS2 BLU/WHT-1 RED-S.P. AL. RD/WT-TB29 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/BLK-1 BLU-1 WHT/RED-1 WHT/BLK-1 WHT-1 R/W-1 RED/BLK-1 RED-1 RED-TILT AL. RED-POWER GN/WT-P.S. TS13 WHT#13-TB13A RED#16-TB16D P1 KS1 TS10 TS11 TS12 TS13 TS14 TS15 TS16 TS17 CB1 HM CR1 CR2 A2 A3 TS10 8 BLU/BLK-4 BLU-4 BLK/WHT-4 BLK-4 W/R-4 WHT/BLK-4 WHT-4 R/W-CURTIS RED/BLK-4 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-4 RED-3 DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM SWITCH PRIMARY BOOM SWITCH EXTEND/RETRACT SWITCH PLATFORM LEVEL SWITCH PLATFORM ROTATE SWITCH JIB SWITCH AUXILIARY SWITCH 15amp. CIRCUIT BREAKER HOUR METER CONTROL RELAY, HORN CONTROL RELAY, AUXILIARY PUMP TRAVEL ALARM DESCENT ALARM Genie Z-34/22 & Genie Z-34/22N Part No. 36540 GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 D 6 - 29 L 5 GRN/WHT-TB19D 7 K CR2 1 6 J C 51 GRN/YEL-CR2 50 GRN/YEL-S.P. 49 48 47 RD/WT-TB46 46 RD/WT-TB47 44 GR/BK-S.P. 43 GRN S.P. 42 41 40 37 36 32 31 30 29 R/W-TB46 28 27 RED-S.P. 23 WT-S.P. 22 BLK S.P. 20 RED S.P. 19 GR/WT-TB36&37 19 GR/WT S.P. 18 GR/BK S.P. 17 GRN S.P. 16 15 OG/BK S.P. 14 ORG S.P. 13 12 RED S.P.-H.M. 11 BU/BK S.P. 10 BLU S.P. 9 8 BK/WT S.P. 7 BLK S.P. 6 WT/RD S.P. 5 WT/BK S.P. 4 WHT S.P. 3 2 RD/BK S.P. 1 RED S.P. B GRN/YEL-TB50 GRN/YEL-LS3 GROUND LIMIT SWITCH OR/B-TB41 RD/WT S.P. GR/BK-D.A. ORG/BLK-TB47 BL/BK-TB19 BU-TB19 WHT-2 BLK-2 BRAKE RELEASE N.C. EMERGENCY BRAKE RELEASE N.C. JIB DOWN JIB UP 48V SUPPLY DRIVE COIL PR1 LIMIT SWITCH STEER LEFT STEER RIGHT BRAKE F.C. REVERSE PR2 FORWARD PR2 BRAKE H.S. TILT ALARM AUXILIARY POWER PR4 KEY SWITCH POWER POWER TO PLATFORM 12V BATTERY SUPPLY LIFT PUMP PR3 PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT RED-LS3 WHT-LS3 BLK-LS3 BU/BK-D.A. BK/RD-CR1 RD/BK-D.A. A PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LIGHT DRIVE ENABLE / HOUR METER SECONDARY BOOM DOWN SECONDARY BOOM UP HORN BOOM RETRACT BOOM EXTEND LIFT FLOW CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT DRIVE FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP First Edition • Third Printing Section 6 • Schematics Ground Control Panel Wiring Diagram (Z-34/22 from serial number 153 to 1733) (Z-34/22N from serial number 304 to 2226) N M L K J I H CR2 1 3 2 A3 A2 4 G 3 5 2 4 6 E D C B A AUXILIARY PUMP 7 1 F 1 5 RED-TB27D 7 8 6 BRN-CR4 8 GRN/WHT-TB19D RED-CH GRN/WHT-CH CR1 1 3 2 4 7 1 3 5 2 4 6 WHT-LS2 HORN 5 BLK/RED-TB9A 7 8 6 8 BRN-MH BLK-HORN RED-SP WHT-HORN BLK-LS1 BLU/WHT-MH RED/WHT-TB46 RED/WHT-TB47 P1 GRN/BLK#44 NC RED#47 NC HOUR METER CR4 (PLATFORM LEVEL CUT-OUT OPTION) 1 RED#12 3 2 4 RED-CR1 7 1 3 5 2 4 6 ORG-TB14D 5 RED-LS2 7 8 6 BRN-TB51A 8 BRN-CR2 BRN-GROUND BLK#7 BLK#22 ORG/BLK-TB15D ORG/BLK-MH ORG-MH J1 KS1 TS17 RED/WHT#46 NO NO WHT#23 LS1 LS2 EXTEND/RETRACT LIMIT SWITCH PRIMARY BOOM LIMIT SWITCH BLK/WHT#8 N.O. WHT/RED#6 N.C. BLK#49-TB49D N.O. ORG-TB14D+TB15D N.C. BLK-TB49C WHT#40-TB40D RED-CR4 WHT#23-TB23C TS15 TS13 CB1 GRN#17 GRN/WHT#19 TS14 TS12 ORG/BLK#15 LS3 LS4 DRIVE ENABLE LIMIT SWITCH SECONDARY BOOM LIMIT SWITCH TS19 N.O. BLK#12-TB12B N.O. N.C. BRN-TB50B N.C. WHT#13-TB13B ORG#14 LABEL RED#1 WHT#4 TS16 BLU#10 RED#20 BLU/BLK#11 WHT/BLK#5 WHT-TILT ALARM RED-CR3 TS11 TS10 EMERGENCY STOP BUTTON KEY SWITCH TS10 TS11 TS12 TS13 TS14 TS15 TS16 TS17 TS19 CB1 TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH BOOM EXTEND/RETRACT SWITCH PLATFORM LEVEL SWITCH PLATFORM ROTATE SWITCH JIB UP/DOWN SWITCH AUXILIARY SWITCH FUNCTION ENABLE SWITCH CIRCUIT BREAKER, CONTROLS, 10A HM CR1 CR2 CR4 CH MH SP A2 A3 J1 HOUR METER CONTROL RELAY - HORN CONTROL RELAY - AUXILIARY PUMP PLATFORM LEVEL CUT-OUT (CE OPTION) WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 WHT-LS1 GRN/WHT-PS GRN/WHT-CR2,CR3 BLU/BLK-MH BLU-MH DESCRIPTION P1 KS1 ORG-1 BLU/BLK-1 BLU-1 RED-CH BLK#40-TB40B WHT#52-TB52B RED#16-TB16B GRN#43 BLU-CH WHT/RED-CH WHT/BLK-CH WHT-CH RED/WHT-CH ORG/BLK-CR4 ORG-CR4 RED/BLK#2 GRN/BLK#44 BLU/BLK-CH RED-TILT ALARM RED#27 GRN/BLK#18 ORG/RED-CH ORG/BLK-CH BLK-TILT ALARM BRN-CH BLK-LS2 BLU/WHT-1 RED-CH RED/WHT-TB29 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 BLK/WHT-MH GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 BLK-MH WHT/RED-MH WHT/BLK-MH WHT-MH RED/WHT-CH WHT-3 RED/WHT-3 RED/BLK-MH RED-MH RED/BLK-3 RED-3 D 52 WHT-LS4 51 BRN-2 50 BRN-LS3 49 48 47 RED-SP ALARM 46 44 GRN/BLK-A3 43 42 41 40 BLK-LS4 37 36 32 31 30 29 28 27 23 22 20 19 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 ORG/BLK-TB41 RED/WHT-SP GRN/BLK-SP GRN-SP ORG/BLK-TB47 BLU/BLK-TB19 BLU-TB19 LIMIT SWITCH HOUR METER BRAKE RELEASE N.C. BRAKE RELEASE REMOTE JIB DOWN JIB UP 48V SUPPLY DRIVE COIL PR1 LIMIT SWITCH STEER LEFT STEER RIGHT BRAKE FLOW CONTROL REVERSE PR2 FORWARD PR2 BRAKE HS TILT ALARM RED-SP AUX PWR PR4 WHT-2 BLK-2 WHT-SP BLK-SP RED-SP PWR TO PLATFORM 12V BATT SUPPLY TB36 & 37 BLU+BLU/BLK GRN/WHT-SP GRN/BLK-SP GRN-SP LIFT PUMP PR3 PLAT ROTATE RIGHT PLAT ROTATE LEFT RED-LS3 ORG-LS2 (OPT) ORG/BLK-SP (OPT) ORG-SP ORG-LS2 WHT-LS3 RED SP-HM BLK-LS3 BLU/BLK-A3 BLU/BLK-SP BLU-SP BLK/RED-CR1 BLK/WHT-SP BLK-SP WHT/RED-SP WHT/BLK-SP WHT-SP RED/BLK-A3 B 2 BRN-SP RED/WHT-TB46 1 C LIMIT SWITCH GROUND CR4 RED/BLK-SP RED-SP 3 4 KEYSWITCH PWR PLAT LEVEL DOWN PLAT LEVEL UP DRIVE ENABLE LIGHT DRIVE ENABLE / HOUR METER SECONDARY BOOM DOWN SECONDARY BOOM UP HORN BOOM RETRACT BOOM EXTEND LIFT FLOW CONTROL TURNTABEL ROTATE LEFT TURNTABEL ROTATE RIGHT 5 6 7 DRIVE FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP A 8 CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL TRAVEL ALARM DESCENT ALARM BRAKE RELEASE JACK Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 6 - 30 First Edition • Third Printing Section 6 • Schematics Ground Control Panel Wiring Diagram (Z-34/22 from serial number 153 to 1733) (Z-34/22N from serial number 304 to 2226) First Edition • Third Printing Section 6 • Schematics Ground Control Panel Wiring Diagram (Z-34/22 from serial number 1734 to 1999) (Z-34/22N from serial number 2227 to 2750) A B C D E F G H I J K L M N BRN 1 RED/WHT BRN A2 A3 ORG LABEL BLK [OPTION 2] BRN-CB2 BRN-5 BRN-2 2 HM J1 KS1 NO TS51 NO AUXILIARY TOGGLE SWITCH TS55 FUNCTION ENABLE TOGGLE SWITCH BLK-7 BLK-6 49 LS1-LS2 JUNCTION RED/WHT-SP BRAKE RELEASE GRN/BLK-SP JIB DOWN GRN-1 43 GRN-SP JIB UP ORG/RED-1 42 PLATFORM ROTATE TOGGLE SWITCH TS58 JIB UP/DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH ORG/RED-L3 SWITCHED 48V ORG-CH OFF-LIMIT SPEED TS62 TURNTABLE ROTATE TOGGLE SWITCH 37 BLU/BLK-MH STEER RIGHT TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH BLU-19D BLU-1 36 BLU-MH STEER LEFT CB1 CIRCUIT BREAKER, CONTROLS, 10A ORG/RED-CH WHT/RED-1 32 WHT/RED-CH JOYSTICK POT. LOW WHT/BLK-1 31 WHT/BLK-CH REVERSE WHT-1 30 WHT-CH FORWARD RED/WHT-CH 2-WIRE POT. RED/WHT-1 29 WHT-TILT RED/BLK-1 28 RED-CR3 RED-1 27 BRN-52A NC HM WHT-2 WHT-SP WHT-7 BLK-2 22 BLK-CR4 BLK-SP +24V TO PLATFORM TB36/TB37 GRN/WHT-CR3 19 GRN/WHT-MH LIFT PUMP GRN/WHT-3 19 GRN/WHT-SP LIFT PUMP BLK-22A GRN/BLK-3 18 GRN/BLK-SP PLAT. ROTATE RIGHT RED-27A GRN-3 17 GRN-SP PLAT. ROTATE LEFT KEYSWITCH POWER KEYSWITCH POWER 16 ORG/RED-CR5 DRIVE ENABLE 15 ORG/BLK-MH * ORG/BLK-SP PLAT. LEVEL DOWN 14 ORG-MH * ORG-SP PLAT. LEVEL UP WHT/RED-6A WHT-5 BLU/RED-3 13 DRIVE ENABLE LIGHT GRN/BLK-18A BLK-5 BLU/WHT-3 12 BLU/BLK-3 11 BLU-3 10 BLU/WHT-CH FOOTSWITCH BLU/BLK-MH BLU/BLK-SP SEC. BOOM DOWN BLU-MH BLU-SP SEC. BOOM UP BLK/RED-3 9 BLK/WHT-3 8 BLK/WHT-MH BLK/WHT-SP BOOM RETRACT BLK-3 7 BLK-MH BLK-SP BOOM EXTEND HORN 6 WHT/RED-MH WHT/RED-SP BOOM FUNCTION F.C. WHT/BLK-3 5 WHT/BLK-MH WHT/BLK-SP TURN. ROTATE RIGHT WHT-MH WHT-SP TURN. ROTATE LEFT WHT-3 4 RED/WHT-3 3 RED/BLK-3 2 RED/BLK-MH RED/BLK-SP PRIMARY BOOM DOWN RED-3 1 RED-MH RED-SP PRIMARY BOOM UP 48V RELAY COIL PWR. 6 TRAVEL ALARM A3 DESCENT ALARM (OPTION) CONTROLLER STATUS LED TS57 TS63 GRN-17A L GRN/WHT-19A R R CB1 E RED-1A ORG/BLK-15A RED TS61 TS59 ORG-14A D D U U TS55 WHT/BLK-5A GRN/BLK-44A TS60 TS58 TS62 D D U U L R BLU/BLK-11A GRN/WHT-19C GRN/WHT-CH 2 A2 L3 BLK/WHT-8A GRN-43A 1 CONTROL RELAY WHT-4A [* SEE OPTIONAL WIRING] [ DENOTES TEST PORT] RED-27D SWITCH PANEL CR RED A ORG ORG/RED-CH MANIFOLD HARNESS SP RED/BLK-2A WHT/RED-3 B NO CIRCUIT BREAKER, CONTROLS RETURN, 10A BLK-7A ORG-3 C KS1 NO ORG/BLK-3 D CHASSIS HARNESS WHT-23A * TS62 CH TS51 RED/WHT-48A * ORG BRAKE RELEASE JACK HOURMETER J1 23 RED/WHT-CR1 J1 HM MH RED-TILT TS55 CB2 P1 RED AUXILIARY PUMP SELECT 23 ORG/RED-3 NC TILT ALARM RED-SP [OPTION 2] TS61 TS60 TS57 WHT/BLK-19D/48D 40 BLK/RED-CR4 TS58 48 44 BLU/BLK-1 ORG TS59 RED/WHT-MH RED/WHT-CR5 GRN/BLK-1 BLU/BLK-19D RED-5 CB1 KEY SWITCH TS51 LS2-LS4 JUNCTION 4 TS63 KS1 BRN-SP BRN-MH DESCRIPTION EMERGENCY STOP BUTTON GROUND WHT/BLK-SP TS57 P1 GROUND 52 NC 3 GROUND 50 BLK-8 NC BRN-CH BRN-CR4 WHT-8 ORG/RED-CR1 P1 52 52 WHT-6 WHT/BLK-SP 5 BRN A2 BLK-22B 3 BLU-10A 4 RED-CH BRN-52A DESCENT ALARM WIRING (OPTION) RED/WHT-TB3D SWITCH PANEL BLK/RED-HORN ORG/RED-42D 7 8 CONTROL RELAY I.D. SPARE WIRE LIST CR1 - SECONDARY 48V POWER CR2 - PRIMARY 48V POWER CR3 - AUXILIARY PUMP CR4 - HORN CR5 - BRAKE RELEASE CR10A - PLATFORM LEVEL CUTOUT (CE OPTION) CR10B - PLATFORM LEVEL CUTOUT (CE OPTION) BLK-1 BLK/WHT-1 BLK/RED-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 GRN/WHT-1 RED-CH RED/WHT-48C ORG/BLK-MH ORG-MH 10B 10A 5 RED-6 RED/BLK-CH TILT SENSOR ORG/RED-16A RED-23D WHT-28D BLK ORG/BLK-15B ORG-14B OPTION NUMBERS 1 - PLATFORM LEVEL CUTOUT 2 - FLASHING BEACON 3 - DESCENT ALARM ORG-6 L3 CB2 BRN-52D ORG/BLK-3 15 ORG/BLK-CR10B ORG/BLK-SP PLATFORM LEVEL DOWN ORG-3 14 ORG-CR10A ORG-SP PLATFORM LEVEL UP PLATFORM LEVEL CUTOUT (CE OPTION) 6 - 31 BLK/RED-9D Genie Z-34/22 & Genie Z-34/22N Part No. 36540 BRN-CH BLK-CH ORG/RED-42A BRN-CB2 First Edition • Third Printing Section 6 • Schematics Ground Control Panel Wiring Diagram (Z-34/22 from serial number 2000 to 3577) (Z-34/22N from serial number 2751 to 4260) N M L K J I H G F E D C RED/WHT BRN-CB2 BLK-[OPTION 2] 52 BRN-CH BRN-CR4 GROUND BRN-5 BRN-2 52 BRN-MH BRN-SP GROUND WHT-6 WHT-8 50 BRN A2 BLK-7 ORG WHT/BLK-SP ORG/RED-CR1 BLK-6 49 RED/WHT-CR5 48 GRN/BLK-1 GRN-1 RED/BLK-TILT (Z34/22N after serial number 4008) (Z34/22 after serial number 3308) CB1 TS51 RED/WHT-TILT (Z34/22N after serial number 4008) (Z34/22 after serial number 3308) J1 ORG/RED-L3 SWITCHED 48V ORG-CH OFF-LIMIT SPEED STEER RIGHT WHT/BLK-19D/48D STEER LEFT BRN-52A WHT/RED-1 32 WHT/RED-CH JOYSTICK POT. LOW WHT/BLK-1 31 WHT/BLK-CH REVERSE WHT-1 30 WHT-CH FORWARD RED/WHT-1 29 RED/WHT-CH 2-WIRE POT. WHT-TILT RED/BLK-1 28 RED-CR3 RED-1 27 RED-SP PLATFORM ROTATE TOGGLE SWITCH CB1 TRACTION CONTROL 23 KEYSWITCH POWER RED-CH TS51 22 BLK-SP +24V TO PLATFORM 19 GRN/WHT-MH LIFT PUMP GRN/WHT-3 19 GRN/WHT-SP LIFT PUMP GRN/BLK-3 18 GRN/BLK-SP PLAT. ROTATE RIGHT WHT-23A GRN-3 17 GRN-SP PLAT. ROTATE LEFT BLK-22A ORG/RED-3 16 ORG/RED-CR5 DRIVE ENABLE KEYSWITCH POWER KS1 RED RED/WHT-48A NO J1 NO RED RED-27A ORG/BLK-15A * ORG/BLK-3 15 ORG/BLK-MH * ORG/BLK-SP PLAT. LEVEL DOWN * ORG-3 14 ORG-MH * ORG-SP PLAT. LEVEL UP BLK/WHT-8A WHT-5 BLU/RED-3 13 DRIVE ENABLE LIGHT WHT/RED-6A BLK-5 BLU/WHT-3 12 BLU/BLK-3 11 1 BLU-3 10 FOOTSWITCH BLU/BLK-MH BLU/BLK-SP SEC. BOOM DOWN BLU-MH BLU-SP SEC. BOOM UP BLK/RED-3 9 8 BLK/WHT-MH BLK/WHT-SP BOOM RETRACT ORG-14A BLK-3 7 BLK-MH BLK-SP BOOM EXTEND GRN/BLK-18A WHT/RED-3 6 WHT/RED-MH WHT/RED-SP BOOM FUNCTION F.C. GRN/WHT-19A GRN/BLK-44A 5 WHT/BLK-MH WHT/BLK-SP TURN. ROTATE RIGHT WHT-3 4 WHT-MH WHT-SP TURN. ROTATE LEFT RED/WHT-3 3 RED/BLK-3 2 RED/BLK-MH RED/BLK-SP PRIMARY BOOM DOWN RED-3 1 RED-MH RED-SP PRIMARY BOOM UP 48V RELAY COIL PWR. A TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH CB1 CIRCUIT BREAKER, CONTROLS, 10A D D CHASSIS HARNESS MANIFOLD HARNESS SP SWITCH PANEL CR_ CONTROL RELAY A2 TRAVEL ALARM (OPTION) A3 DESCENT ALARM (OPTION) L3 CONTROLLER STATUS LED U U TS58 GRN-43A RED/BLK-2A 5 L R RED-1A GRN-17A TS62 WHT-4A D TS55 L GRN/WHT-19C 6 TS60 TS55 R U BLU/BLK-11A BLK-22B 4 TS57 WHT/BLK-5A GRN/WHT-CH CH MH 3 E TS61 [* SEE OPTIONAL WIRING] CR3 PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS62 U WHT/BLK-3 CR2 TS61 2 TS59 HORN RED-27D SECONDARY BOOM UP/DOWN TOGGLE SWITCH D R BLK/WHT-3 B TS60 BLK-7A TS63 BLU/WHT-CH C PLATFORM LEVEL TOGGLE SWITCH HOURMETER BATTERY LIGHT TS62 JIB UP/DOWN TOGGLE SWITCH TS59 HM 25 BLK-CR4 TS58 CIRCUIT BREAKER, CONTROLS RETURN, 10A WHT-2 CR1 TS57 BRAKE RELEASE JACK 24 ORG/RED-CH FUNCTION ENABLE TOGGLE SWITCH J1 GRN/WHT-CR3 D AUXILIARY TOGGLE SWITCH TS55 AUXILIARY PUMP SELECT BLK-2 RED/WHT-CR1 KEY SWITCH TS51 CB2 LIFT LOCKOUT 23 HM NC TB36/TB37 TS57 KS1 TILT ALARM WHT-7 ORG EMERGENCY STOP BUTTON NC 26 WHT-SP P1 RED-TILT ORG TS60 ORG/RED-CH 40 BLU-MH TS59 ORG JIB UP BLU/BLK-MH BLK/RED-CR4 TS61 GRN-SP 36 RED-5 TS58 43 SWITCH PANEL 37 NO TS63 JIB DOWN BLU-1 WHT/BLK-SP NO GRN/BLK-SP BLU/BLK-1 [OPTION 2] KS1 BRAKE RELEASE 44 BLU-19D HM P1 LS1-LS2 JUNCTION RED/WHT-MH BLU/BLK-19D P1 NC LS2-LS4 JUNCTION RED/WHT-SP 42 ORG/RED-1 BLK-8 NC BRN A2 A DESCRIPTION LABEL BRN A3 B CR4 BLU-10A BRN-52A RED/WHT-TB3D BLK/RED-HORN DESCENT ALARM WIRING (OPTION) ORG/RED-42D RED-CH RED/WHT-48C CONTROL RELAY I.D. CR1 - SECONDARY 48V POWER CR2 - PRIMARY 48V POWER CR3 - AUXILIARY PUMP CR4 - HORN CR5 - BRAKE RELEASE CR10A - PLATFORM LEVEL CUTOUT (CE OPTION) CR10B - PLATFORM LEVEL CUTOUT (CE OPTION) OPTION NUMBERS SPARE WIRE LIST BLK-1 BLK/WHT-1 BLK/RED-1 BLU/WHT-1 BLU/RED-1 GRN/WHT-1 ORG-1 ORG/BLK-1 Z34/22N after serial number 4008 Z34/22 after serial number 3308 ORG/BLK-MH ORG-MH Z34/22N before serial number 4009 Z34/22 before serial number 3309 CR10B CR10A CR5 7 BLK/RED-9D RED-6 RED/BLK-CH ORG/RED-16A TILT SENSOR RED WHT ORG/BLK-15B ORG-14B ORG-6 BLK ORG/BLK-3 15 ORG/BLK-CR10B ORG/BLK-SP PLATFORM LEVEL DOWN ORG-3 14 ORG-CR10A ORG-SP PLATFORM LEVEL UP 1 - PLATFORM LEVEL CUTOUT 2 - FLASHING BEACON 3 - DESCENT ALARM C B BRN-CH TILT SENSOR RED/WHT-23D RED-23D RED/BLK-28D WHT-28D BRN-CB2 8 Genie Z-34/22 & Genie Z-34/22N 6 - 32 BLK BRN-CB2 L3 CB2 BRN-52D PLATFORM LEVEL CUTOUT (CE VERSION ONLY) A L3 CB2 BLK-CH ORG/RED-42A Part No. 36540 BRN-52D BRN-CH BLK-CH ORG/RED-42A First Edition • Third Printing Section 6 • Schematics Ground Control Panel Wiring Diagram (Z-34/22 from serial number 2000 to 3577) (Z-34/22N from serial number 2751 to 4260) First Edition • Third Printing Section 6 • Schematics Ground Control Panel Wiring Diagram (Z-34/22 from serial number 3578 to 4799) (Z-34/22N from serial number 4261 to 5619) A B C D F G [OPTION 2] A3 BRN A2 WHT-2 134 RED-A6 RED-KSI KEYSWITCH POWER BLK [OPTION 2] 52 BRN-CH BRN-CR4 GROUND BRN-5 BRN-2 52 BRN-MH BRN-SP GROUND WHT-6 WHT-8 50 ORG/RED-CR1 J1 RED/WHT-48A TS55 FUNCTION ENABLE SWITCH TS57 PLATFORM ROTATE SWITCH 44 GRN/BLK-SP JIB DOWN TS58 JIB UP/DOWN SWITCH 43 GRN-SP JIB UP TS59 PLATFORM LEVEL SWITCH ORG/RED-L3 SWITCHED 48V ORG/RED-CH BRAKE RELEASE RED/WHT-SP TS60 SECONDARY BOOM UP/DOWN SWITCH STEER RIGHT TS61 PRIMARY BOOM UP/DOWN SWITCH BLU-19D BLU-1 36 BLU-MH STEER LEFT TS62 TURNTABLE ROTATE SWITCH WHT/RED-1 32 WHT/RED-CH JOYSTICK POT. LOW WHT/BLK-1 31 WHT/BLK-CH REVERSE TS63 BOOM EXTEND/RETRACT SWITCH 30 WHT-CH FORWARD CB1 CIRCUIT BREAKER, CONTROLS, 10A P1 RED/WHT-1 29 RED/WHT-CH 2-WIRE POT. CB2 CIRCUIT BRKR., CONTROLS RETURN, 10A NC RED/BLK-TILT RED/BLK-1 28 RED-CR3 RED-1 J1 BRAKE RELEASE JACK NC HM HOURMETER ORG-CH OFF-LIMIT SPEED AUXILIARY PUMP SELECT RED-SP LIFT LOCKOUT 25 BATTERY LIGHT 24 TRACTION CONTROL BLK-C23-4 22 GRN/WHT-CR3 19 RED-5 BLK-CR4 GRN/BLK WHT/BLK-19D/48D CH CHASSIS HARNESS MH MANIFOLD HARNESS SWITCH PANEL BLK-SP +24V TO PLATFORM SP GRN/WHT-MH LIFT PUMP BRN-52A CR_ CONTROL RELAY A2 BRK. REL./TRAVEL ALARM CB1 KS1 19 GRN/WHT-SP LIFT PUMP GRN/BLK-3 18 GRN/BLK-SP PLAT. ROTATE RIGHT GRN-3 17 GRN-SP PLAT. ROTATE LEFT A3 DESCENT ALARM (OPTION) ORG/RED-3 16 ORG/RED-CR5 DRIVE ENABLE A6 PLATFORM OVERLOAD ALARM BLK-22A L3 CONTROLLER STATUS LED ORG/BLK-15A L45 PLATFORM OVERLOAD LED BLK/WHT-8A ORG/BLK-3 15 ORG/BLK-MH * ORG/BLK-SP PLAT. LEVEL DOWN * ORG-3 14 ORG-MH * ORG-SP PLAT. LEVEL UP WHT-5 BLU/RED-3 13 BLK-5 BLU/WHT-3 12 BLU/BLK-3 11 BLU-3 10 BLK/RED-3 9 BLK/WHT-3 8 BLK/WHT-MH BLK/WHT-SP BOOM RETRACT BLK-3 7 BLK-MH BLK-SP BOOM EXTEND WHT/RED-3 6 WHT/RED-MH WHT/RED-SP BOOM FUNCTION F.C. WHT/BLK-3 5 WHT/BLK-MH WHT/BLK-SP TURN. ROTATE RIGHT WHT-MH WHT-SP DRIVE ENABLE LIGHT HM RED-CH GRN/WHT-3 * TS51 L45 RED/134A RED-C23-6 RED-27A BLK-7A WHT/RED-6A TS59 TS63 BLK/RED-CR4 5 BLU/WHT-CH FOOTSWITCH BLU/BLK-MH BLU/BLK-SP SEC. BOOM DOWN BLU-MH BLU-SP SEC. BOOM UP TS61 TS58 TS57 ORG RED/WHT-CR1 D R U ORG-14A GRN/BLK-18A 4 3 RED/BLK-3 2 RED/BLK-MH RED/BLK-SP PRIMARY BOOM DOWN RED-3 1 RED-MH RED-SP PRIMARY BOOM UP GRN-43A RED/BLK-2A 48V RELAY COIL PWR. U U WHT/BLK-5A D RED-C23-7 GRN/WHT-19C CR1 RED-27D GRN/WHT-CH CR2 CR3 BLK-22B BLU-10A CR4 1 3 4 5 6 7 8 12 BRN-52A RED/WHT-TB3D SWITCH PANEL C23 BLK/RED-HORN DESCENT ALARM WIRING (OPTION) ORG/RED-42D U33 SPARE WIRE LIST CR1 - SECONDARY 48V POWER CR2 - PRIMARY 48V POWER CR3 - AUXILIARY PUMP CR4 - HORN CR5 - BRAKE RELEASE CR10A - PLATFORM LEVEL CUTOUT (CE OPTION) CR10B - PLATFORM LEVEL CUTOUT (CE OPTION) BLK-1 BLK/WHT-1 BLK/RED-1 BLU/WHT-1 BLU/RED-1 GRN/WHT-1 ORG-1 ORG/BLK-1 ORG/BLK-MH ORG-MH CR5 8 BLK/RED-9D RED-CH RED/WHT-48C CR10A CR10B RED-6 RED/BLK-CH ORG/RED-16A TILT SENSOR WHT ORG-6 BLK OPTION NUMBERS ORG/BLK-3 15 ORG/BLK-CR10B ORG/BLK-SP PLATFORM LEVEL DOWN 1 - PLATFORM LEVEL CUTOUT 2 - FLASHING BEACON 3 - DESCENT ALARM ORG-3 14 ORG-CR10A ORG-SP PLATFORM LEVEL UP L3 CB2 BRN-52D PLATFORM LEVEL CUTOUT (CE VERSION ONLY) 6 - 33 Genie Z-34/22 & Genie Z-34/22N RED ORG/BLK-15B ORG-14B Part No. 36540 L U BLU/BLK-11A CONTROL RELAY I.D. TS60 TS55 ORG/RED-CH R TS62 WHT-4A TS55 7 TS57 GRN-17A BRN/GND GRN/BLK H6 BLK-2 BLU/WHT-1 A B D RED-1A BLK 22C 6 TS62 C TS61 D L TURN. ROTATE LEFT WHT-3 RED/WHT-3 TS58 GRN/BLK-44A RED A6 TS60 E HORN ORG D TS59 TS63 GRN/WHT-19A ORG A6 TILT ALARM 26 TB36/TB37 BRN A2 BLU/BLK-MH 40 27 N RED 134B 37 NO 4 AUXILIARY SWITCH GRN-1 WHT-7 M RED C23-1 BLU/BLK-1 WHT/BLK-SP NO L LS1-LS2 JUNCTION RED/WHT-MH 23 TS51 K BLU/RED-1 LS2-LS4 JUNCTION GRN/BLK-1 CB1 KS1 KEY SWITCH TS51 48 42 J BLU/BLK-19D P1 HM KS1 49 WHT-1 NC EMERGENCY STOP BUTTON BLK-6 ORG/RED-1 I DESCRIPTION P1 RED/WHT-CR5 BLK-8 NC KEYSWITCH POWER BRN-CB2 WHT/BLK-SP ORG 134A RED/WHT-TILT BLK-7 3 H LABEL BRN 1 2 E BRN-CH BLK-CH ORG/RED-42A A C B RED/WHT-23D RED/BLK-28D BRN-CB2 R First Edition • Third Printing Section 6 • Schematics Ground Control Panel Wiring Diagram (Z-34/22 after serial number 4799) (Z-34/22N after serial number 5619) N M L K J I H G F E D C B A 1 SWITCH PANEL RD C23-1 RD/WH-48A TILT SENSOR RD WH BK A3 A C B A2 A6 2 RD/WH-134D BR-52A RD/BK-C1B-2 BR-CB2 BR-52A A2 RD 134B L3 BL/RD C2B-1 CB2 BR-52D BK-C49-7 BR-C48-3 OR/RD-42A GN/BK WH/BK-19D/48D BR-52A 3 BR C32-12 NC P1 HM NC TO TERMINAL BASE AND CONNECTORS HM P1 NC RD-C48-1 4 CB1 NC TS51 KS1 CB1 L45 RD/134A BK-22A TS51 RD-C23-6 RD-27A 5 OR/BK-15A L45 BK-7A KS1 BK/WH-8A LABEL WH/RD-6A DESCRIPTION TS59 TS63 TS63 TS59 OR TS58 TS61 TS57 OR KEY SWITCH TS51 AUXILIARY TOGGLE SWITCH TS55 FUNCTION ENABLE TOGGLE SWITCH D R U TS57 PLATFORM ROTATE TOGGLE SWITCH TS58 JIB UP/DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH BL/WH C1-12 TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH BK 22C GN-43A TS62 TURNTABLE ROTATE TOGGLE SWITCH BK C7-1 RD/BK-2A BR HM(-) CIRCUIT BREAKER, CONTROLS RETURN, 10A HM HOURMETER CH CHASSIS HARNESS MH MANIFOLD HARNESS SP SWITCH PANEL CR CONTROL RELAY A2 TRAVEL ALARM A3 DESCENT ALARM (OPTION) A6 PLATFORM OVERLOAD (CE OPTION) L3 CONTROLLER STATUS LED L45 PLATFORM OVERLOAD LED GN/BK A6 CB2 TS61 GN/BK-44A BR/GND CIRCUIT BREAKER, CONTROLS, 10A GN/WH-19A BK P22BAT BOOM EXTEND/RETRACT TOGGLE SWITCH 6 GN/BK-18A RD-C23-6 TS63 CB1 E OR-14A BL/WH C132PLI DESCENT ALARM WIRING (OPTION) TS62 KS1 BK 22C TS60 TS55 EMERGENCY STOP BUTTON RD A6 OR P1 D D U U TS57 L TS58 R RD-1A GN-17A WH/BK-5A TS62 WH-4A D 7 TS60 L TS55 R U BL/BK-11A RD-C32-7 BL-10A 1 3 4 5 6 7 8 12 8 C32 U33 PLATFORM OVERLOAD (OPTION) Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 6 - 34 First Edition • Third Printing Section 6 • Schematics Ground Control Panel Wiring Diagram (Z-34/22 after serial number 4799) (Z-34/22N after serial number 5619) First Edition • Third Printing Section 6 • Schematics Ground Control Terminal Strip Wiring Diagram (Z-34/22 after serial number 4799) (Z-34/22N after serial number 5619) N M L K J I C52 G F TERMINAL BASE (TB) LS4-SECONDARY UP/DOWN RD/WH (FLASH. BEACON OPT.) C8 LS3-DRIVE ENABLE C10 C134PWR RD-A6 (CE OPTION) RD-KSI-4 KEYSWITCH POWER C134PWR BR-CB2 BK (FLASH. BEACON OPT.) 52 BR- MH BR-CR4 GROUND BATGND BR C7B-3 52 BR BR-SP GROUND BATGND 48 RD/WH-MH RD/WH-SP BRAKE RELEASE C48BRK OR/RD C49-10 WH/BK-SP OR/RD C2B-4 42 OR/RD-L3 SWITCHED 48V R42BAT BL/BK-19D BL/BK C1B-11 37 BL/BK-MH STEER RIGHT C37SCW BL-19D BL C1B-10 36 BL-MH STEER LEFT C36SCC RD-CR3 RD C1B-1 27 RD-SP AUXILIARY PUMP SELECT C27AUX WH C10-2 BK-C23-4 22 BK-CR4 +24V TO PLATFORM P22BAT BK-SP GR/WH-CR3 19 GR/WH-MH LIFT PUMP C19LPE GR/WH C4B-7 19 GR/WH-SP LIFT PUMP C19LPE OR/RD C8-1 OR/RD C4B-4 16 OR/RD-CR5 DRIVE ENABLE C16DE (CE OPTION) OR/BK C4B-3 15 OR/BK-MH OR/BK-SP PLATFORM LEVEL DOWN C15PLD (CE OPTION) OR C4B-2 14 OR-MH OR-SP PLATFORM LEVEL UP C14PLU BK C8-3 BL/WH C3B-12 12 BL/WH-CH FOOTSWITCH C12FTS BL/BK C3B-11 11 BL/BK-MH BL/BK-SP SECONDARY BOOM DOWN C11SBD BL C3B-10 10 TB36/TB37 C7B BL-MH BL-SP SECONDARY BOOM UP C10SBU BK/WH C3B-8 8 BK/WH-MH BK/WH-SP BOOM RETRACT C8PBR BK C3B-7 7 BK-MH BK-SP BOOM EXTEND C7PBE WH/RD C3B-6 6 WH/RD-MH WH/RD-SP BOOM FUNCTION F.C. C6MFV WH/BK C3B-5 5 WH/BK-MH WH/BK-SP TURNTABLE ROTATE RIGHT C5TRR WH C3B-4 4 WH-MH WH-SP TURNTABLE ROTATE LEFT C4TRL RD/BK C3B-2 2 RD/BK-MH RD/BK-SP PRIMARY BOOM DOWN C2PBD RD C3B-1 1 RD-MH RD-SP PRIMARY BOOM UP C1PBU C B A WIRES FROM CONNECTOR TO CONNECTOR CIRCUIT# FROM TO 1 DESC. WH J2 C11-4 C10-2 BK J1 C11-3 C52-1 LS1-LS2 JUNCTION C44JD C2B-6 SP JIB DOWN GR C43JU C2B-5 SP JIB UP OR C40LS C52-2 CH OFF-LIMIT SPEED WH/RD C32JSL C1B-6 CH JOYSTICK POT. LOW WH/BK C31REV C1B-5 CH REVERSE WH C30FWD C1B-4 CH FORWARD RD/WH C29JSH C1B-3 CH 2-WIRE POT. GR/BK LS2-LS4 JUNCTION RD/BK C28TTA TILT-C C1B-2 TILT ALARM GR/BK C18PRR C4B-6 SP PLATFORM ROTATE RIGHT GR C17PRL C4B-5 SP PLATFORM ROTATE LEFT BL/RD C13DEL C8-4 C4B-1 DRIVE ENABLE LIGHT BK/RD C9HRN CR4 C3B-9 HORN RD/WH C3BAT CR1 C3B-3 48V RELAY COIL PWR. BL/WH C132PLI C1B-12 C32-3 PLAT OVERLOAD INPUT (OPTION) BL/RD C133PLA C2B-1 A6(-) PLAT OVERLOAD ALARM (OPTION) 2 3 4 B C D D WIRES BR C8-2 WH/BK-SP LS1-PRIMARY EXTEND/RETRACT CIRCUIT # KEYSWITCH POWER WH C7B-2 OR/RD-CR1 LS2-PRIMARY UP/DOWN DESCRIPTION RD-C32-1 134 134 E RD/WH-TILT RD/WH-CR5 C11 CABLE#2 H A C4B CABLE#3 C3B TO TERMINAL BASE RD-27D GR/WH-19C 5 OR/RD-C48-2 C2B GR/WH-C49-11 OR RELAY BLOCK CR1 CR2 CR3 BK-22A CR4 CABLE#1 BR-52A C1B RD/WH-C3B-3 BK/RD-MH-HORN OR/RD-42D CONTROL RELAY I.D. CR1 - SECONDARY 48V POWER CR2 - PRIMARY 48V POWER CR3 - AUXILIARY PUMP CR4 - HORN CR5 - BRAKE RELEASE CR10A - PLAT. LEVEL CUTOUT (CE ONLY) CR10B - PLAT. LEVEL CUTOUT (CE ONLY) 6 BK/RD-C3B-9 RD-C49-1 RD/WH-48D CR10A CR5 REF. OR/BK-MH OR-MH 30 CR10B RD-C11-1 RD/BK-C49-2 86 85 87A OR/RD-16A 7 87 BR-52D MANIFOLD HARNESS (MH) OR/BK-15A OR-14A C48 8 OR/BK C11-2 CHASSIS HARNESS (CH) C49 OR/BK C4B-3 15 OR/BK-CR10B OR/BK-SP PLAT. LEVEL DOWN OR C4B-2 14 OR-CR10A OR-SP PLAT. LEVEL UP PLATFORM LEVEL CUTOUT (CE VERSION ONLY) Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 6 - 35 First Edition • Third Printing Section 6 • Schematics Ground Control Terminal Strip Wiring Diagram (Z-34/22 after serial number 4799) (Z-34/22N after serial number 5619) First Edition • Third Printing Section 6 • Schematics Platform Control Box Wiring Diagram (Z-34/22 before serial number 1734) (Z-34/22N before serial number 2227) A B C D E F G H I J K L M N 1 TS9 L.V.I./B.C.I. (OPTION) TS8 TS1 NC 3 TS4 TS3 4 5 4 DISCHARGE P2 SET TO "N" TILT ALARM NO BCI 5 + L1 7 6 LVI P3 RESET SET TO "A" - 2 8 3 3 2 1 TS2 NC CABLE 110 #3 TS6 TS7 TS5 4 RED BCI (OPTION) FOOT SWITCH CABLE + #2 8 TS18 (OPTION) BCI BLK/RED GRN RED MAXOUT A THRESHOLD -+ LABEL P2 RED BP1 R + L RED RED RED/WHT D X BLK - + B 2 3 1 4 2 3 1 CR5 DESCRIPTION EMERGENCY STOP BUTTON P3 HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM SPEED CONTROLLER TS1 TURNTABLE ROTATE TOGGLE SWITCH TS2 SECONDARY BOOM TOGGLE SWITCH TS3 PRIMARY BOOM TOGGLE SWITCH TS4 EXTEND/RETRACT TOGGLE SWITCH TS5 PLATFORM LEVEL TOGGLE SWITCH TS6 PLATFORM ROTATE TOGGLE SWITCH TS7 JIB BOOM UP/DOWN TOGGLE SWITCH TS8 AUXILIARY POWER TOGGLE SWITCH TS9 DRIVE ENABLE TOGGLE SWITCH L1 DRIVE ENABLE LIGHT BCI BATTERY CHARGE INDICATOR TS18 LIFT/DRIVE SELECT (OPTION) GRN/WHT#45-1 BLU/RED#39-1 BLU/WHT#48-1 BLK/RED#35-1 BLK/WHT#34-1 RED-JIB BLK#33-1 BRN-F.S. ORG/RED-3 RED/BLK-1 BRN WHT-FS CR3 COIL + ORG/RED-1 BLU/WHT-3 WHT-FS WHT/BLK-3 WHT-3 BLU/BLK-3 BLU-3 GRN/BLK#44-1 GRN#43-1 GRN/WHT-3 Part No. 36540 WHT/RED-3 ORG/BLK-3 ORG-3 RED/BLK-3 RED-3 BRN-2 BLK/WHT-3 BLUE-JIB GRN/BLK-3 ORG-JIB GRN-3 Genie Z-34/22 & Genie Z-34/22N BLK-3 BLU/RED-3 BLK/RED-3 ORG/RED#42-1 WHT#30-1 WHT/BLK#31-1 WHT/RED#32-1 ORG/BLK#41-1 RED/WHT-3 ORG#40-1 BLU/BLK#37-1 6 - 36 RED/WHT#29-1 BLU#36-1 BRN-JIB RED-TILT ALARM WHT-2 BLK-FS BLK-2 RED#27-1 WHT-JIB BLK-JIB 8 WHT DP1 4 5 WHT/BLK 7 6 7 JIB #1 5 R 8 5 CABLE - 6 6 7 SPARE WIRES First Edition • Third Printing Section 6 • Schematics Platform Control Box Wiring Diagram (Z-34/22 from serial number 1734 to 1834) (Z-34/22N from serial number 2227 to 2448) N M L K J I H G F E D C B A 1 WHT TS15 ORG/BLK TS1 2 RED TS12 P3 A1 L1 NO RED 3 TS11 TS13 NC P2 CABLE #3 TS10 NC TS7 TS9 110 4 CABLE #2 TS8 BCI F.S. RED BRN GRN BLK/RED BRN-JIB CABLE #1 JIB 5 BP1 BRN 2 3 5 6 7 8 R 9 10 DESCRIPTION EMERGENCY STOP BUTTON HORN BUTTON DRIVE CONTROLLER BOOM FUNCTION SPEED CONTROLLER AUXILIARY TOGGLE SWITCH PLATFORM ROTATE TOGGLE SWITCH JIB BOMM UP/DOWN TOGGLE SWITCH PLATFORM LEVEL TOGGLE SWITCH SECONDARY BOOM UP/DOWN TOGGLE SWITCH PRIMARY BOOM UP/DOWN TOGGLE SWITCH TURNTABLE ROTATE TOGGLE SWITCH EXTEND/RETRACT TOGLE SWITCH DRIVE ENABLE TOGGLE SWITCH TILT ALARM DRIVE ENABLE LIGHT BATTERY CHARGE INDICATOR RED/BLK-1 BLU/WHT-3 ORG/RED WHT/BLK-3 ORG/BLK-1 WHT-3 BLU/BLK-3 BLU-3 GRN/BLK-1 GRN-1 GRN/WHT-3 WHT/RED-3 ORG/BLK-3 ORG-3 RED-3 RED/BLK-3 GRN-3 GRN/BLK-3 BLK/WHT-3 BLK-3 BLU/RED-3 BLU/BLK-1 BLU-1 WHT-FS WHT-1 WHT/BLK-1 WHT/RED-1 ORG/RED-1 RED/WHT-1 RED/WHT-3 WHT-2 BLK-F.S. BLK-2 BLK/RED-3 BLUE-JIB RED-1 ORG-JIB WHT-JIB BLK-JIB REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED. 4 BRN-2 L 1 LABEL P2 P3 DP1 BP1 TS1 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS15 A1 L1 BCI 6 7 8 REMOVE JUMPER JP1 FOR CE VERSION. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 6 - 37 First Edition • Third Printing Section 6 • Schematics Platform Control Box Wiring Diagram (Z-34/22 from serial number 1734 to 1834) (Z-34/22N from serial number 2227 to 2448) Section 6 • Schematics First Edition • Third Printing Platform Control Box Wiring Diagram (Z-34/22 from serial number 1835 to 2060) (Z-34/22N from serial number 2449 to 2870) A B C D E F G H I J K L M N 1 WHT WHT SPARE WIRES ________________ BLK-1 BLK/WHT-1 BLK/RED-1 BLU/WHT-1 BLU/RED-1 GRN/WHT-1 ORG-1 ORG/BLK-1 TS15 2 TS1 L1 TS7 TS9 TS12 A1 R R D L L NO U WHT P3 3 CABLE #3 U D U D R E NC TS10 NC TS13 F.S. CABLE #2 ORG/RED 4 LOAD SENSE (OPTION) RED RED TS11 P2 U D TS8 BRN BP1 BLK/RED RED GRN 5 JIB CABLE #1 BCI (OPTION) BRN-JIB BRN 6 RED 1 L 2 3 4 5 6 7 7 8 BRN-2 DP1 DESCRIPTION LABEL R P2 EMERGENCY STOP BUTTON P3 HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY POWER TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB BOOM UP/DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM UP/DOWN TOGGLE SWITCH TS11 PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 PRIMARY EXTEND/RETRACT TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH A1 TILT ALARM L1 DRIVE ENABLE LIGHT BCI BATTERY CHARGE INDICATOR (OPTION) 9 10 1 NOTES: 8 RED/BLK-1 BLU/WHT-3 ORG/RED-3 WHT/BLK-3 BLU/BLK-3 WHT-3 BLU-3 WHT/RED-3 GRN/BLK-3 GRN-3 GRN-1 GRN/WHT-3 RED/BLK-3 GRN/BLK-1 RED-3 Part No. 36540 ORG-3 ORG/BLK-3 BLK-3 BLK/WHT-3 BLU/RED-3 BLU/BLK-1 Genie Z-34/22 & Genie Z-34/22N BLU-1 WHT-FS WHT/BLK-1 WHT-1 WHT/RED-1 RED/WHT-1 RED/WHT-3 WHT-2 ORG/RED-1 BLK-FS BLK-2 BLK/RED-3 RED-1 BLUE-JIB ORG-JIB WHT-JIB BLK-JIB 6 - 38 2 1 REMOVE JUMPER JP1 FOR CE VERSION. 2 REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED. First Edition • Third Printing Section 6 • Schematics Platform Control Box Wiring Diagram (Z-34/22 from serial number 2061 to 3577) (Z-34/22N from serial number 2871 to 4260) N M L K J I H G F E D C B A 1 WHT WHT SPARE WIRES ________________ BLK-1 BLK/WHT-1 BLK/RED-1 BLU/WHT-1 BLU/RED-1 GRN/WHT-1 ORG-1 ORG/BLK-1 TS15 L1 TS1 TS12 TS7 TS9 A1 R R D 3 L L NO U WHT P3 CABLE #3 U D U D R E LOAD SENSE (OPTION) RED RED TS11 P2 NC TS10 NC TS13 2 F.S. CABLE #1 JIB D U CABLE #2 ORG/RED 4 TS8 BCI (OPTION) BRN 5 BP1 BLK/RED RED GRN LABEL P2 P3 BRN-JIB BRN 1 2 3 4 5 6 7 8 L R 9 10 BRN-2 DP1 HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY POWER TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB UP/DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGLE SWITCH TS10 SECONDARY BOOM UP/DOWN TOGGLE SWITCH TS11 RED DESCRIPTION EMERGENCY STOP BUTTON PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 EXTEND/RETRACT TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH A1 TILT ALARM L1 DRIVE ENABLE LIGHT BCI BATTERY CHARGE INDICATOR (OPTION) 6 7 1 NOTES: REMOVE JUMPER JP1 FOR CE VERSION. 2 REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED. 8 RED/BLK-1 ORG/RED-3 BLU/WHT-3 WHT/BLK-3 WHT-3 BLU/BLK-3 BLU-3 WHT/RED-3 GRN/BLK-3 GRN-3 GRN-1 GRN/WHT-3 GRN/BLK-1 RED-3 RED/BLK-3 ORG-3 ORG/BLK-3 BLK-3 BLK/WHT-3 BLU/RED-3 BLU/BLK-1 BLU-1 WHT-FS WHT/BLK-1 WHT-1 WHT/RED-1 RED/WHT-1 RED/WHT-3 WHT-2 ORG/RED-1 BLK-FS BLK-2 BLK/RED-3 RED-1 BLUE-JIB ORG-JIB WHT-JIB BLK-JIB 2 1 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 6 - 39 First Edition • Third Printing Section 6 • Schematics Platform Control Box Wiring Diagram (Z-34/22 from serial number 2061 to 3577) (Z-34/22N from serial number 2871 to 4260) First Edition • Third Printing Section 6 • Schematics Platform Control Box Wiring Diagram (Z-34/22 after serial number 3577) (Z-34/22N after serial number 4260) N M L K J I H G F E D C B A 1 WHT WHT SPARE WIRES ________________ BLK-1 BLK/WHT-1 BLK/RED-1 ORG-1 ORG/BLK-1 TS15 L1 TS1 TS12 TS7 TS9 R L L A1 R U LS18 RED NO D WHT P3 3 CABLE #3 TS11 U D U D R E RED NC P2 2 RED NC TS10 TS13 F.S. CABLE #1 JIB U D CABLE #2 ORG/RED 4 TS8 BCI (OPTION) BRN LABEL BLK/RED RED GRN BP1 BRN-JIB L4 BRN RED/BLK RED 1 2 3 4 5 6 7 8 L R 9 10 BRN-2 DP1 DESCRIPTION P2 EMERGENCY STOP BUTTON P3 HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY SWITCH TS7 PLATFORM ROTATE SWITCH TS8 JIB UP/DOWN SWITCH TS9 PLATFORM LEVEL SWITCH TS10 SECONDARY BOOM UP/DOWN SWITCH TS11 PRIMARY BOOM UP/DOWN SWITCH TS12 TURNTABLE ROTATE SWITCH TS13 EXTEND/RETRACT SWITCH TS15 DRIVE ENABLE SWITCH A1 TILT ALARM L1 DRIVE ENABLE LIGHT BCI BATTERY CHARGE INDICATOR (OPTION) L4 TILT ALARM LED L48 PLATFORM OVERLOAD LED 5 6 L48 GRN/BLK 1 7 NOTES: 1 REMOVE JUMPER JP1 FOR CE VERSION. BLU/RED-1 BLU/WHT-1 RED/BLK-1 BLU/WHT-3 WHT-2 WHT/BLK-3 ORG/RED-3 WHT-3 BLU/BLK-3 WHT/RED-3 BLU-3 GRN/BLK-3 GRN-1 GRN-3 GRN/WHT-3 GRN/BLK-1 RED-3 RED/BLK-3 ORG-3 BLK/WHT-3 ORG/BLK-3 BLU/RED-3 BLK-3 BLU/BLK-1 BLU-1 WHT-FS WHT-1 WHT/RED-1 WHT/BLK-1 RED/WHT-1 RED/WHT-3 ORG/RED-1 BLK-FS BLK-2 BLK/RED-3 RED-1 BLUE-JIB ORG-JIB WHT-JIB BLK-JIB Part No. 36540 8 Genie Z-34/22 & Genie Z-34/22N 6 - 40 First Edition • Third Printing Section 6 • Schematics Platform Control Box Wiring Diagram (Z-34/22 after serial number 3577) (Z-34/22N after serial number 4260) Section 6 • Schematics First Edition • Third Printing Hydraulic Schematic (Z-34/22 before serial number 674) (Z-34/22N before serial number 935) A B C D E F G H I J K L M N N.O. COM 1 STEER CYLINDER N.C. K M BRAKES M I S2 G J L M O S1 2 0.052“ (1.32 mm) 0.040" (1 mm) 0.085" (2.15 mm) BRAKE N P H PLATFORM LEVEL SLAVE CYLINDER JIB BOOM CYLINDER STEER/BRAKE MANIFOLD 0.025" (0.63 mm) ORFICE DELETED Z-34/22 AFTER SERIAL NUMBER 581 Z-34/22N AFTER SERIAL NUMBER 767 T 3 PLATFORM ROTATE SECONDARY CYLINDER 4 M AUXILIARY PUMP 0.5 GPM (1.9 L/min) 0.032" (0.81 mm) PRIMARY PUMP 1.7 GPM (6.4 L/min) M 3000 PSI (207 bar) 8:1 100 MICRON MESH 5 EXTENSION CYLINDER PRIMARY CYLINDER TURNTABLE ROTATE MASTER CYLINDER 2500 PSI (172 bar) 3:1 2500 PSI (172 bar) 3:1 5.9 CU. IN. /REV TANK, 4 GALLON (15.1 Liters) 6 P1 BOOM FUNCTION MANIFOLD G1 C1 C2 M1 C5 C6 C7 C8 C AP 1750 PSI (121 bar) AA 3000 PSI (207 bar) 3:1 AU AG AR AS 1600 PSI (110 bar) 1400 PSI (96 bar) AT 1800 PSI (124 bar) A AL AK 8 AF AE AJ AD AI AH P AC P2 AM 0.050" (1.27 mm) T2 T1 Genie Z-34/22 & Genie Z-34/22N E D B AQ 1750 PSI (121 bar) 25 PSI (1.7 bar) 6 - 41 C4 T1 AB 5 MICRON C3 JIB/PLATFORM ROTATE MANIFOLD 0.025" T2 PR1 (0.76 mm) PR2 AN AO 3200 PSI (221 bar) 7 M2 2500 PSI (172 bar) 3:1 3000 PSI (207 bar) 3:1 3000 PSI (207 bar) 1.5:1 Part No. 36540 T First Edition • Third Printing Section 6 • Schematics Hydraulic Schematic (Z-34/22 from serial number 674 to 1733) (Z-34/22N from serial number 935 to 2226) N M L K J I H G F N.O. COM STEER CYLINDER N.C. E D B A 1 K M M BRAKES I S2 C G J L M O S1 0.052“ (1.32 mm) 0.040" (1 mm) 0.085" (2.15 mm) BRAKE 2 N P H PLATFORM LEVEL SLAVE CYLINDER JIB BOOM CYLINDER STEER/BRAKE MANIFOLD T 3 PLATFORM ROTATE PRIMARY CYLINDER SECONDARY CYLINDER M AUXILIARY PUMP 0.5 GPM (1.9 L/min) PRIMARY PUMP 1.7 GPM (6.4 L/min) M 100 MICRON MESH EXTENSION CYLINDER 4 0.032" (0.81 mm) 3000 PSI (207 bar) 8:1 TURNTABLE ROTATE MASTER CYLINDER 5.9 CU. IN. /REV 2500 PSI (172 bar) 3:1 2500 PSI (172 bar) 3:1 5 TANK, 4 GALLON (15.1 Liters) P1 G1 C1 C2 M1 M2 BN BP BQ C4 C5 C6 C7 JIB UP/DOWN, PLATFORM ROTATE MANIFOLD 0.025” T2 PR1 (0.76 mm) PR2 C8 T1 FUNCTION MANIFOLD BO BB BA BS 1400 PSI (96 bar) BT 1800 PSI (124 bar) A F BG D B 7 25 PSI (1.7 bar) BU E 1500 PSI (103 bar) 3:1 3000 PSI (207 bar) 3:1 BK BL BF BE BJ BD BI BH 0.028” (0.89 mm) T P BC 8 P2 BM 6 C BR 1600 PSI (110 bar) 3200 PSI (221 bar) 5 MICRON C3 2500 PSI (172 bar) 3:1 3000 PSI (207 bar) 3:1 3000 PSI (207 bar) 1.5:1 0.050" (1.27 mm) ORFICE ADDED Z34/22 AFTER SERIAL NUMBER 781 Z34/22N AFTER SERIAL NUMBER 1030 T2 T1 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 6 - 42 First Edition • Third Printing Section 6 • Schematics Hydraulic Schematic (Z-34/22 from serial number 674 to 1733) (Z-34/22N from serial number 935 to 2226) Section 6 • Schematics First Edition • Third Printing Hydraulic Schematic (Z-34/22 from serial number 1734 to 2005) (Z-34/22N from serial number 2227 to 2771) A B C D E F G H I J JIB BOOM CYLINDER 1 K L M N PLATFORM ROTATE 2 UP 3000 PSI DOWN (207 bar) 3:1 J1 PR1 C F P AUXILIARY PUMP 0.5 GPM (1.9 L/min) PRIMARY PUMP 2.1 GPM (7.9 L/min) M M STEER CYLINDER M 5 MASTER CYLINDER 100 MICRON MESH COM CT P1 BOOM FUNCTION MANIFOLD 7 T PRIMARY CYLINDER EXTENSION CYLINDER 0.032“ (0.81 mm) 5.9 CU. IN. /REV CL HYDRAULIC TANK 5 GALLON (18.9 L) 6 B TURNTABLE ROTATE BRAKES 10 MICRON D SECONDARY CYLINDER 3000 PSI (207 bar) 8:1 M E 0.025 inch / 0.64 mm (before serial number: Z34-1982 and Z34N-2548) 0.022 inch / 0.56 mm (from serial number: Z34-1892 to 2005 and Z34N-2548 to 2771) 0.030” (0.76 mm) Orifice removed after serial number: Z34-1891 and Z34N-2547 4 A JIB UP/DOWN, PLATFORM ROTATE MANIFOLD PR2 PLATFORM LEVEL SLAVE CYLINDER 3 BRAKE G1 N.O. N.C. PS S1 S2 L2 L1 P2 TR1 CO 3200 PSI (221 bar) 0.045“ (1.14 mm) CN CH CP 3000 PSI (207 bar) 1.5:1 SC1 SC2 CE 3000 PSI (207 bar) 3:1 PC1 PC2 CF 2500 PSI (172 bar) 3:1 RET EXT CG CM CC CJ CQ TR2 CD CR CI 3000 PSI (207 bar) 3:1 CB 1100 PSI (76 bar) 0.045” (1.14 mm) 0.8 GPM (3.6 L/min) 8 CA CX T1 6 - 43 J2 V1 3000 PSI V2 (207 bar) 3:1 CY 1.5 GPM (6.8 L/min) 1600 PSI (110 bar) CU 1400 PSI (97 bar) CV 1800 PSI (124 bar) CK CW T2 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 6 • Schematics Hydraulic Schematic (Z-34/22 from serial number 2006 to 2900) (Z-34/22N from serial number 2772 to 3532) N M L K J I H G F E D C B A JIB BOOM CYLINDER 1 PLATFORM ROTATE 2 ROTATE MANIFOLD EXT PR1 RET 3000 PSI 207 bar 1.5:1 J1 PR2 3300 PSI 228 bar 3:1 J2 PR1 3 PR2 A B C 0.3 GPM PLATFORM LEVEL SLAVE CYLINDER 1.14 L/min T 4 JIB MANIFOLD PRIMARY CYLINDER SECONDARY CYLINDER STEER CYLINDER M M EXTENSION CYLINDER 0.032 0.81 mm 5 TURNTABLE ROTATE (WORM DRIVE) BRAKES 3000 PSI 207 bar 4.5:1 5.9 CU. IN./REV 97 cc /REV MASTER CYLINDER 6 3000 PSI 207 bar 1.5:1 CL 3000 PSI 207 bar 3:1 N.O. COM CT M 3200 PSI 221 bar G1 CO CR N.C. PS S2 P1 PRIMARY PUMP 2.1 GPM 8 L/min S1 AUXILIARY PUMP 0.5 GPM 1.9 L/min BRAKE P2 L2 L1 TR2 TR1 CC 0.045 inch 1.14 mm CN CH 10 MICRON CP SC2 SC1 PC1 PC2 EXT RET CD CM CB 7 CJ M CQ 2500 PSI 172 bar 3:1 3000 PSI 207 bar 3:1 CI 0.045 inch 1.14 mm 1100 PSI 76 bar CW 100 MESH CX 0.8 GPM 3 L/min CA CY 1600 PSI 110 bar 1400 PSI 110 bar CE CF CU 1800 PSI 124 bar CG CV CK 8 1.5 GPM 5.7 L/min Orifice added after serial number: Z-34/22-2894 Z-34/22N-3517 HYDRAULIC TANK 0.035 inch 0.89 mm T1 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N CS T2 6 - 44 First Edition • Third Printing Section 6 • Schematics Hydraulic Schematic (Z-34/22 from serial number 2006 to 2900) (Z-34/22N from serial number 2772 to 3532) First Edition • Third Printing Section 6 • Schematics Hydraulic Schematic (Z-34/22 after serial number 2900) (Z-34/22N after serial number 3532) N M L K J I H G F E D C B A 1 JIB BOOM CYLINDER PLATFORM ROTATE 2 EXT PR1 RET 3000 PSI 207 bar 1.5:1 J1 PR2 3300 PSI 228 bar 3:1 J2 PR1 B A PLATFORM LEVEL SLAVE CYLINDER 3 PR2 C 0.3 GPM 1.14 L/min T 4 JIB MANIFOLD EXTENSION CYLINDER SECONDARY CYLINDER PRIMARY CYLINDER 0.032 0.81 mm M STEER CYLINDER BRAKES 5 M TURNTABLE ROTATE (WORM DRIVE) 3000 PSI 207 bar 4.5:1 0.090 inch 2.28 mm Regen added after serial numbers: Z34-3216 Z34N-3767 5.9 CU. IN./REV 97 cc /REV MASTER CYLINDER .090 orifice added after serial numbers: Z34-3327 Z34N-4017 CL N.O. COM CT M 3200 PSI 221 bar G1 CO CR BRAKE PS S2 P1 PRIMARY PUMP 2.1 GPM 8 L/min S1 AUXILIARY PUMP 0.5 GPM 1.9 L/min N.C. P2 L2 L1 TR2 TR1 0.045 inch 1.14 mm CB 3000 PSI 207 bar 3:1 CJ CP CI 0.045 inch 1.14 mm 10 MICRON 100 MESH CX CH PC2 EXT RET 0.8 GPM 3 L/min CA 1100 PSI 76 bar CW CY 1600 PSI 110 bar 1600 PSI 110 bar 2800 PSI 193 bar CE CF CG CU CV 7 Removed after serial number: Z34-3215 Z34N-3766 CM CC CN PC1 CD M CQ SC2 SC1 2500 PSI 172 bar 3:1 3000 PSI 207 bar 3:1 3000 PSI 207 bar 1.5:1 6 CK 8 1.5 GPM 5.7 L/min HYDRAULIC TANK 0.035 inch 0.89 mm T1 Part No. 36540 Genie Z-34/22 & Genie Z-34/22N CS T2 6 - 45 First Edition • Third Printing Section 6 • Schematics Hydraulic Schematic (Z-34/22 after serial number 2900) (Z-34/22N after serial number 3532) First Edition • Third Printing Section 7 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Observe and Obey: Repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Perform disassembly procedures to the point where repairs can be completed. Then to re-assemble, perform the disassembly steps in reverse order. Symbols Legend Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Repair any machine damage or malfunction before operating the machine. Before Repairs Start: Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Read, understand and obey the safety rules and operating instructions in the Genie Z-34/22 & Genie Z-34/22N Operator's Manual. Be sure that all necessary tools and parts are available and ready for use. Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. • Machine parked on a flat, level surface • Boom in stowed position Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. • Turntable rotated with the boom between the non-steering wheels • Key switch in the OFF position with the key removed • Wheels chocked Green—used to indicate operation or maintenance information. Indicates that a specific result is expected after performing a series of steps. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7-1 First Edition • Third Printing Section 7 • Repair Procedures Platform Controls 1-1 Controllers Drive Controller Adjustments The drive controller (joystick) is connected by a control cable to the drive motor controller located under the non-steer end drive chassis cover. Maintaining the controllers at the proper setting is essential to safe machine operation. Each controller should operate smoothly and provide proportional speed control through its entire range of motion. For further information or assistance, contact the Genie Industries Service Department. Z-34/22: before serial number 153 Z-34/22N: before serial number 304 Do not adjust the controllers unless the static battery supply voltage is above 24V DC. This procedure will require the use of two multi-meters. One will be used for measuring amperage and the other for voltage. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Individual trim potentiometers (trimpots) are used to adjust various output signals from the drive and boom function speed controllers. The trimpots will be identified as the following: a b d a b c d c boom function speed controller drive printed circuit board drive controller brake printed circuit board • Max out trim potentiometer (max out trimpot) • High range trim potentiometer (max out trimpot) • Lo range trim potentiometer (lo range trimpot) • Dual range trim potentiometer (lo range trimpot) • Threshold trim potentiometer (threshold trimpot) • Ramp rate trim potentiometer (ramp rate trimpot) 1 Block the steering wheels. 2 Center a lifting jack of ample capacity (15000 lbs/6804 kg) under the drive chassis between the non-steering wheels. 7-2 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM CONTROLS 3 Lift the wheels off the ground approximately 1 to 2 inches (2.5 to 5 cm) and place jack stands under the drive chassis for support. 4 Open the platform control box lid and locate the brake controller printed circuit board. 6 Connect the black (-) lead from an ammeter to the white/red wire that was removed from the brake circuit board. Connect the red (+) lead to the "A" terminal on the brake controller printed circuit board. 7 Locate the drive controller printed circuit board. a a b b c c d d e e f f g g h h Brake Drive a b c d e f g h i not used not used terminal "X", terminal "-", ground terminal "+", terminal "A", proportional output threshold adjustable trimpot max out adjustable trimpot 5 Disconnect the white/red wire from the "A" terminal on the brake controller printed circuit board. Part No. 36540 Brake a b c d e f g h i Drive max out adjustable trimpot threshold adjustable trimpot terminal "A", proportional output not used terminal "-", ground terminal (blank) not used terminal "R", activates max out range lo range adjustable trimpot 8 Connect the red (+) lead from a volt meter to the "A" terminal on the drive controller printed circuit board. Connect the black (-) lead to ground. Genie Z-34/22 & Genie Z-34/22N 7-3 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM CONTROLS 9 Turn the key switch to platform controls and pull both Emergency Stop buttons out to the ON position. 10 Set the threshold on the brake circuit board: Press down the foot switch and slowly move the control handle off center until you hear the pump motor turn ON. Adjust the amperage to 0.16 amps. Turn the threshold trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage. 11 Set the max out on the brake circuit board: Press down the foot switch and slowly move the control handle off center until you hear the pump motor turn OFF. Adjust the amperage to 0.91 amps. Turn the max out trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage. 12 Set the threshold on the drive circuit board: Press down the foot switch and slowly move the control handle off center until you see 0.28 to 0.3 amps on the ammeter. Adjust the threshold trimpot on the drive circuit board to 0.8 to 0.9V DC. Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 13 Set the max out on the drive circuit board: Press down the foot switch and slowly move the control handle all the way to the FORWARD position. Adjust the max out trimpot on the drive circuit board to 5 to 5.2V DC. Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 14 Raise the primary boom approximately 2 feet (0.6 m). 7-4 15 Set the lo range on the drive circuit board: Press down the foot switch and move the control handle all the way to the FORWARD position. Adjust the lo range trimpot on the drive circuit board to 2.4 to 2.7V DC. Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 16 Lower the boom to the stowed position and remove the jack stands from under the drive chassis. 17 Raise the primary boom approximately 2 feet (0.6 m). 18 Create start and finish lines by marking two lines on the ground 40 feet (12.2 m) apart. Choose a reference point on the machine as a visual reference for use when crossing the start and finish lines. 19 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 20 Continue at full speed and note the time when the reference point crosses the finish line. 21 Adjust the lo range trimpot on the drive circuit board to achieve a 40 second drive speed time. Turn the lo range trimpot clockwise to decrease the time or counterclockwise to increase the time. 22 Lower the primary boom to the stowed position. 23 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 24 Continue at full speed and note the time when the reference point crosses the finish line. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM CONTROLS 25 Adjust max out trimpot on the drive circuit board to achieve the specified drive speed time (refer to table below). Turn the high range trimpot clockwise to decrease the time or counterclockwise to increase the time. Drive Controller Adjustments Z-34/22 from serial number 153 to 1733 Z-34/22N from serial number 304 to 2226 Do not adjust the controllers unless the static battery supply voltage is above 24V DC. Drive controller specifications Brake board Threshold (when pump motor turns ON) Max out (when pump motor turns OFF) 0.16 amps This procedure will require the use of two multi-meters. One will be used for measuring amperage and the other for voltage. 0.91 amps Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Drive board Threshold 0.8 to 0.9V DC (when amp output is 0.28 to 0.3 amps) Max out 5 to 5.2V DC (with boom stowed and joystick in full forward position) Lo range 2.4 to 2.7V DC (with boom raised and joystick in full forward position) 1 Block the steering wheels and center a lifting jack under the drive chassis between the nonsteer tires. Drive speeds (maximum) Z-34/22 stowed position 49:1 drive hubs 3.1 mph 5 km/h 40 ft/9.1 sec 12.2 m/9.1 sec 35:1 drive hubs 4 mph 6.4 km/h 40ft/6.8 sec 12.2 m/6.8 sec Drive speeds (maximum) Z-34/22N stowed position 49:1 drive hubs 2.8 mph 40 ft/10 sec 35:1 drive hubs 3.4 mph 40ft/8 sec 4.5 km/h 12.2 m/10 sec a 5.5 km/h 12.2 m/8 sec b Drive speed, 0.6 mph 1 km/h booms raised or extended 40 ft/40 sec 12.2 m/40 sec c a b c Part No. 36540 Genie Z-34/22 & Genie Z-34/22N boom function speed controller drive and brake printed circuit board drive controller 7-5 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM CONTROLS 2 Raise the drive chassis approximately 1 to 2 inches (2.5 to 5 cm) off the ground and place jack stands under the chassis for support. 3 Open the platform control box lid and locate the printed circuit board on the drive controller. a b c d e f g h i j k a b c d e f g h i j k terminal "R", activates max out range terminal "D", drive output terminal "X" terminal "-", ground terminal "+", positive terminal "B", brake output drive lo range trimpot drive threshold trimpot drive max out trimpot brake threshold trimpot brake max out trimpot 4 Disconnect the white/red wire from the "B" terminal on the printed circuit board. 7-6 5 Connect the black (-) lead from an ammeter to the white/red wire that was removed from the circuit board. Connect the red (+) lead to the "B" terminal on the printed circuit board. 6 Connect the red (+) lead from a volt meter to the "D" terminal on the drive controller printed circuit board. Connect the black (-) lead to ground. 7 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 8 Set the brake threshold on the circuit board: Press down the foot switch and slowly move the control handle off center until you hear the pump motor turn ON. Adjust the amperage to 0.16 amps. Turn the threshold trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage. 9 Set the brake max out on the circuit board: Press down the foot switch and slowly move the control handle off center until you hear the pump motor turn OFF. Adjust the amperage to 0.91 amps. Turn the max out trimpot adjustment screw clockwise to increase the amperage or counterclockwise to decrease the amperage. 10 Set the drive threshold on the circuit board: Press down the foot switch and slowly move the control handle off center until you see 0.28 to 0.3 amps on the ammeter. Hold the control handle in this position and adjust the drive threshold trimpot on the circuit board to 0.8 to 0.9V DC. Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM CONTROLS 11 Set the drive max out on the circuit board: Press down the foot switch and slowly move the control handle all the way to the FORWARD position. Adjust the max out trimpot on the circuit board to 5 to 5.2V DC. Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 20 Lower the primary boom to the stowed position. 12 Raise the primary boom approximately 2 feet (0.6 m) to activate the drive limit switch. 23 Adjust max out trimpot on the drive circuit board to achieve the specified drive speed time (refer to table below). Turn the max out trimpot clockwise to decrease the time or counterclockwise to increase the time. 13 Set the drive lo range on the circuit board: Press down the foot switch and move the control handle all the way to the FORWARD position. Adjust the drive lo range trimpot on the circuit board to 2.4 to 2.7V DC. Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 14 Lower the boom to the stowed position and remove the jack stands from under the drive chassis. 15 Raise the primary boom approximately 2 feet (0.6 m) to activate the drive limit switch. 16 Create start and finish lines by marking two lines on the ground 40 feet (12.2 m) apart. Choose a reference point on the machine as a visual reference for use when crossing the start and finish lines. 17 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 18 Continue at full speed and note the time when the reference point crosses the finish line. 19 Adjust the drive lo range trimpot on the circuit board to achieve a 40 second drive speed time. Turn the lo range trimpot clockwise to decrease the time or counterclockwise to increase the time. Part No. 36540 21 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 22 Continue at full speed and note the time when the reference point crosses the finish line. Drive controller specifications Brake board Threshold (when pump motor turns ON) Max out (when pump motor turns OFF) 0.16 amps 0.91 amps Drive board Threshold 0.8 to 0.9V DC (when amp output is 0.28 to 0.3 amps) Max out 5 to 5.2V DC (with boom stowed and joystick in full forward position) Lo range 2.4 to 2.7V DC (with boom raised and joystick in full forward position) Drive speeds (maximum) Z-34/22 stowed position 49:1 drive hubs 3.1 mph 5 km/h 40 ft/9.1 sec 12.2 m/9.1 sec 35:1 drive hubs 4 mph 6.4 km/h 40ft/6.8 sec 12.2 m/6.8 sec Drive speeds (maximum) Z-34/22N stowed position 49:1 drive hubs 2.8 mph 40 ft/10 sec 4.5 km/h 12.2 m/10 sec 35:1 drive hubs 3.4 mph 5.5 km/h 40ft/8 sec 12.2 m/8 sec Genie Z-34/22 & Genie Z-34/22N 7-7 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM CONTROLS 3 Locate the diode between the black/red wire from the boom function speed controller and the white/red wire. Boom Function Speed Controller Adjustments Do not adjust the controllers unless the static battery supply voltage is above 24V DC. 4 Connect the red (+) lead from a volt meter to the wire connector of the white/red wire next to the diode. Connect the black (-) lead to ground. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 5 Turn the boom function speed controller to the CREEP position. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 2 Open the platform control box lid and locate the boom function speed controller. e a f b c 6 Set the threshold: Press down the foot switch, and move the primary boom toggle switch to the DOWN position. Adjust the voltage to 8V DC. Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 7 Turn the boom function speed controller to the 9 position. 8 Set the max out: Press down the foot switch, then move the primary boom toggle switch to the DOWN position. Adjust the voltage to 15.5V DC. Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. If equipped: d a b c d e f 7-8 black/red wire diode white/red wire boom function speed controller max out trimpot threshold trimpot 9 Set the ramp rate: Turn the ramp rate trimpot to obtain a 2 second delay from 0 to 15.5V DC. Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time. Boom function speed controller specifications Threshold (controller turned to "CREEP") 8V DC Max out (controller turned to "9") 15.5V DC Ramp (controller turned to "9") Added after serial numbers: Z34-1924 Z34N-2553 2 seconds Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM CONTROLS 3 Press down the foot switch. Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity. 1-2 Foot Switch How to Test the Foot Switch Test 1 Turn the key switch to the OFF position and separate the wiring quick disconnect plug from the platform toe board. 2 Do not press down the foot switch. Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity. Test Desired result red to black no continuity (infinite Ω) red to white no continuity (infinite Ω) black to white continuity (zero Ω) Desired result red to black continuity (zero Ω) red to white no continuity (infinite Ω) black to white no continuity (infinite Ω) FOOT SWITCH Do not use the color of the connector as a guide for these tests. Use the actual wire color to identify which connector to use for testing. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7-9 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM CONTROLS 1-3 Toggle Switches Test Toggle switches used for single function switching are single pole double throw (SPDT) switches. Dual function switching requires a double pole double throw (DPDT) switch. terminal 1 to 2, 3, 4, 5 & 6 How to Test a Toggle Switch terminal 2 to 4, 5 & 6 no continuity (infinite Ω) terminal 3 to 4, 5 & 6 no continuity (infinite Ω) terminal 4 to 5 & 6 no continuity (infinite Ω) Left position Continuity is the equivalent of 0 to 3 ohms. A simple continuity tester may not accurately test the switch. This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches. 1 Turn the key switch to the OFF position. Tag and disconnect all wiring from the toggle switch to be tested. 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed below to check for continuity. Left 3 1 3 2 Single pole double throw (SPDT) Right Center 1 1 2 terminal 2 to 3 terminal 5 to 6 Center position no continuity (infinite Ω) continuity (zero Ω) continuity (zero Ω) There are no terminal combinations that will produce continuity (infinite Ω) Right position terminal 1 to 2 continuity (zero Ω) terminal 1 to 3, 4, 5 & 6 no continuity (infinite Ω) terminal 2 to 3, 4, 5 & 6 no continuity (infinite Ω) terminal 3 to 4, 5 & 6 no continuity (infinite Ω) terminal 4 to 5 continuity (zero Ω) terminal 4 to 6 no continuity (infinite Ω) terminal 5 to 6 no continuity (infinite Ω) 3 2 1 2 3 1 2 3 1 2 3 4 5 6 4 5 6 4 5 6 1 2 3 1 2 3 1 2 3 Double pole double throw (DPDT) 7 - 10 Desired result Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures Platform Components 2-1 Platform 2-2 Platform Leveling Slave Cylinder How to Remove the Platform The slave cylinder and the platform rotator are the two primary supports for the platform. The slave cylinder keeps the platform level through the entire range of primary boom motion. It operates in a closed-circuit hydraulic loop with the master cylinder. The slave cylinder is equipped with counterbalance valves to prevent platform movement in the event of a hydraulic line failure. 1 Separate the foot switch wiring quick disconnect plug from the platform toeboard. 2 Remove the platform control box mounting fasteners, then lower the control box. If your machine is equipped with an air line to platform option, the air line must be disconnected from the platform before removal. How to Remove the Slave Cylinder 3 Place blocks under the platform for support and carefully lower the platform on the blocks. Before cylinder removal is considered, bleed the slave cylinder to be sure there is no air in the closed loop hydraulic circuit. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 4 Remove the platform mounting fasteners and remove the platform. Component damage hazard. Platform can be damaged if the fasteners are overtightened. Part No. 36540 1 Extend the boom until the slave cylinder barrel-end pivot pin is accessible. 2 Raise the boom slightly and place blocks under the platform for support. Lower the boom until the platform is resting on the blocks. 3 Remove the pin retaining fastener from the rod-end pivot pin. Do not remove the pin. Genie Z-34/22 & Genie Z-34/22N 7 - 11 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM COMPONENTS 4 Remove the external snap ring from the barrel-end pivot pin. How to Bleed the Slave Cylinder 5 Place a block of wood under the barrel end of the slave cylinder. 1 Raise the jib boom to a horizontal position. 6 Use a soft metal drift to remove the rod-end pivot pin. 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system. 7 Use a soft metal drift to remove the barrel-end pivot pin. 8 Carefully pull the cylinder out of the boom. Crushing hazard. The slave cylinder will fall unless it is properly supported. 9 Tag and disconnect the hydraulic hoses from the slave cylinder and connect them together with a connector. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 - 12 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM COMPONENTS 2-3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees. 4 Remove the six mounting bolts from the platform mounting weldment. Remove the center bolt and slide the platform mounting weldment off of the platform rotator. 5 Support the platform rotator with a suitable lifting device. Do not apply any lifting pressure. 6 Remove the pin retaining fasteners from the jib boom and leveling links to platform rotator pivot pins. Do not remove the pins. How to Remove the Platform Rotator When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 7 Support the jib boom, jib boom cylinder and leveling links with an overhead crane. 8 Use a soft metal drift to drive both pivot pins out. Remove the platform rotator from the machine. 1 Remove the platform. See 2-1, How to Remove the Platform. Crushing hazard. The platform rotator may become unbalanced and fall if it is not properly supported. 2 Tag, disconnect and plug the hydraulic hoses from the platform rotate manifold. Cap the manifold fittings. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Support the platform mounting weldment, but do not apply any lifting pressure. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 13 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM COMPONENTS How to Bleed the Platform Rotator This procedure will require two people. 1 Turn the key switch to ground controls and pull out the Emergency Stop button to the ON position. 2 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the primary boom toggle switch in the up direction until the platform is approximately 6 feet (1.8 m) off the ground. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom toggle switch in the UP direction until the platform is approximately 6 feet (1.8 m) off the ground. 3 Connect a clear hose to the top bleed valve. Place the other end of the hose in a container to collect any discharge. Open the top bleed valve, but do not remove it. 4 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the platform rotate toggle switch to the right for approximately 5 seconds, then release it. Repeat three times. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side and move the platform rotate toggle switch to the right for approximately 5 seconds, then release it. Repeat three times. Crushing hazard. Keep clear of the platform during rotation. a b c d a b c d 7 - 14 Genie Z-34/22 & Genie Z-34/22N clear hose top bleed valve bottom bleed valve container Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures PLATFORM COMPONENTS 5 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the platform rotate toggle switch to the left for approximately 5 seconds, then release it. Repeat three times. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable switch to either side and move the platform rotate toggle switch to the left for approximately 5 seconds, then release it. Repeat three times. 6 Fully rotate the platform to the left and continue holding the platform rotate toggle switch until air stops coming out of the bleed valve. Immediately release the platform rotate toggle switch and close the bleed valve. 7 Rotate the platform to the right until the platform is centered. 8 Connect the clear hose to the bottom bleed valve and open the valve. Do not remove the valve. 9 Move the platform rotate toggle switch to the right and continue holding the platform rotate toggle switch until air stops coming out of the bleed valve. Crushing hazard. Keep clear of the platform during rotation. 10 Close the bleed valve and remove the hose. 11 Rotate the platform full left and right and inspect the bleed valves for leaks. 12 Turn the key switch to the OFF position and clean up any hydraulic oil that may have spilled. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 15 First Edition • Third Printing Section 7 • Repair Procedures Jib Boom Components 5 Remove the mounting fasteners from the jib boom/platform rotate manifold. Do not remove the hoses. 3-1 Jib Boom Component damage hazard. Hoses and cables can be damaged if they are twisted or kinked. How to Remove the Jib Boom Perform this procedure with the boom in the stowed position. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. See 2-1, How to Remove the Platform. 2 Remove the platform mounting weldment and the platform rotator. See 2-3, How to Remove the Platform Rotator. 3 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the jib boom lift cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 6 Attach a lifting strap from an overhead crane to the jib boom. 7 Remove the pin retaining fastener from the jib boom pivot pin at the jib boom bellcrank. Use a soft metal drift to remove the pin, then remove the jib boom from the jib boom bellcrank. Crushing hazard. The jib boom will fall when the pin is removed if it is not properly supported. 8 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. 9 Remove both of the jib boom compression arms from the bellcrank. 10 Attach a lifting strap from an overhead crane to the rod-end of the jib boom lift cylinder. 11 Use a soft metal drift to remove the jib boom lift cylinder rod-end pivot pin, then remove the jib boom lift cylinder from the jib boom bellcrank. Crushing hazard. The jib boom lift cylinder will fall when the pin is removed if it is not properly supported. 4 Remove the cable cover from the side of the jib boom. 7 - 16 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures JIB BOOM COMPONENTS 12 Support and secure the jib boom bellcrank to an appropriate lifting device. 13 Remove the pin retaining fasteners from the slave cylinder rod-end pivot pin. Do not remove the pin. 14 Remove the pin retaining fasteners from the jib boom mounting weldment at the jib boom bellcrank. Use a soft metal drift to remove the pin. 3-2 Jib Boom Bell Crank How to Remove the Jib Boom Bell Crank Perform this procedure with the boom in the stowed position. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 15 Use a soft metal drift to remove the slave cylinder rod-end pivot pin. 16 Remove the jib boom bellcrank from the boom. Crushing hazard. The jib boom bellcrank may become unbalanced and fall when the pins are removed if it is not properly supported and secured to the lifting device. 1 Remove the platform. See 2-1, How to Remove the Platform. 2 Remove the Jib Boom, See 3-1, How to Remove the Jib Boom. 3 Support and secure the jib boom bell crank to an appropriate lifting device. 4 Remove the pin retaining fasteners from the slave cylinder rod-end pivot pin. Do not remove the pin. 5 Remove the pin retaining fasteners from the jib boom bell crank at the extension boom. Use a soft metal drift to remove the pin. 6 Use a soft metal drift to remove the slave cylinder rod-end pivot pin. 7 Remove the jib boom bell crank from the extension boom. Crushing hazard. The jib boom bell crank may become unbalanced and fall when the pins are removed if it is not properly supported and secured to the lifting device. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 17 First Edition • Third Printing Section 7 • Repair Procedures JIB BOOM COMPONENTS 2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the jib boom lift cylinder. 3-3 Jib Boom Lift Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the jib boom slightly and place blocks under the platform mounting weldment. Lower the jib boom until the platform is resting on the blocks. 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. 4 Use a soft metal drift to tap the rod-end pivot pin half way out and lower one of the leveling links to the ground. Tap the pin the other direction and lower the opposite leveling link. Do not remove the pin. 5 Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder. 6 Remove the pin retaining fasteners from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pivot pin. 7 Use a soft metal drift to remove the jib boom lift cylinder rod-end pivot pin. Remove the jib boom lift cylinder from the machine. Crushing hazard. The jib boom lift cylinder may fall when the pins are removed if it is not properly supported by the overhead crane. 7 - 18 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures Primary Boom Components 4-1 Plastic Cable Track 4-2 Primary Boom The primary boom cable track guides the cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom. How to Shim the Primary Boom How to Repair the Plastic Cable Track 1 Extend the boom until the wear pads are accessible. Component damage hazard. The primary boom cable track can be damaged if it is twisted. Measure each wear pad. Replace the pad if it is less than 0.41 inch (1 cm) thick. If the pad is more than 0.41 inch (1 cm) thick, perform the following procedure. 2 Loosen the wear pad mounting fasteners. 3 Install the new shims under the wear pad to obtain zero clearance and zero drag. 4 Tighten the mounting fasteners. 5 Extend and retract the boom through an entire cycle. Check for tight spots that could cause scraping or binding. a Always maintain squareness between the outer and inner boom tubes. b a b link separation point lower clip 1 Use a slotted screwdriver to pry down on the lower clip. 2 Repeat step 1 for each link. 3 To remove a single link, open the lower clip and then use a screw driver to pry the link to the side. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 19 First Edition • Third Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 6 Open the platform control box. How to Remove the Primary Boom Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Perform this procedure with the boom in the stowed position. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. See 2-1, How to Remove the Platform. 7 Label and disconnect each wire of the 4 cables in the platform control box. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 8 Pull all of the cables out of the platform control box. 9 Tag, disconnect and plug the hydraulic hoses from the slave cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 10 Tag, disconnect and plug the hydraulic hoses from the jib/rotate manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 2 Remove the platform rotator. See 2-3, How to Remove the Platform Rotator. 3 Remove the jib boom. See 3-1, How to Remove the Jib Boom. 4 Remove the jib boom bellcrank. See 3-2, How to Remove the Jib Boom Bellcrank. 5 Locate the 4 cables from the primary boom cable track to the platform control box. Number each cable and its entry location at the platform control box. 7 - 20 11 Remove the upper cable track mounting fasteners from the platform end of the boom. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 12 Remove the cable track mounting fasteners, then remove the cable track from the boom and lay it flat on the ground. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 20 Attach a similar lifting device to the lift cylinder. 21 Place support blocks under the cylinder, across the secondary boom. 22 Remove the pin retaining fastener from the boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The boom lift cylinder will fall unless it is properly supported. 13 Remove all of the hose and cable clamps from the underside of the primary boom. 14 Remove the turntable end cover. 15 Remove the extension boom drive limit switch from the side of the primary boom at the pivot end. Do not disconnect the wiring. 16 Pull all of the electrical cables and hydraulic hoses out of the plastic cable track. 17 Remove the pin retaining fastener from the master cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Pull the cylinder back and secure it from moving. 23 Lower the rod end of the lift cylinder onto support blocks. 24 Remove the pin retaining fastener from the primary boom pivot pin. 25 Remove the primary boom pivot pin with a soft metal drift, then carefully remove the boom from the machine. 18 Tag, disconnect and plug the extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Crushing hazard. The boom may become unbalanced and fall when it is removed from the machine If the overhead crane is not properly attached. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 19 Attach an overhead 5 ton crane to the center point of the boom. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 21 First Edition • Third Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 7 Support and slide the extension tube out of the primary boom tube. Place the extension tube on blocks for support. How to Disassemble the Primary Boom Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced. The extension cylinder can be removed without completely disassembling the boom. See 4-4, How to Remove the Extension Cylinder. 1 Remove the boom. See 4-2, How to Remove the Primary Boom. 2 Place blocks under the extension cylinder for support. During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. 8 Remove the retaining rings from the extension cylinder rod-end pivot pins at the platform end of the extension tube. Use a soft metal drift to remove the pins. 9 Support and slide the extension cylinder out of the pivot end of the boom extension tube. Place the extension cylinder on blocks for support. 3 Remove the retaining fasteners from the extension cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin. 4 Remove and label the location of the wear pads from the top side of the boom tube at the platform end of the boom. During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. 10 Remove and label the wear pads from the extension cylinder. Pay careful attention to the location and amount of shims used with each wear pad. Pay careful attention to the location of each wear pad. 5 Carefully rotate the base end of the extension cylinder until the pin mounting bore is in a vertical position. 6 Support the extension tube with an overhead crane at the platform end of the boom. Crushing hazard. The boom tubes will fall when they are removed from the boom if they are not properly supported. 7 - 22 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 4-3 Primary Boom Lift Cylinder 4 Place a block of wood across the upper secondary boom to support the cylinder when the rod-end pivot pin is removed. The primary boom lift cylinder raises and lowers the primary boom. The primary boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. 5 Place a rod through the compression arm pivot pin and twist to remove the pin. Lower the compression arm down. How to Remove the Primary Boom Lift Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 6 Support the primary boom lift cylinder with a lifting device. 7 Remove the pin retaining fastener from the primary boom lift cylinder rod-end pivot pin. Then use a soft metal drift to remove the pin. 8 Lower the rod end of the cylinder onto the blocks that were placed on the upper secondary boom. 9 Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. 1 Raise the primary boom enough to access the primary boom lift cylinder rod-end pivot pin. 2 Attach an overhead crane to the primary boom for support. Do not lift it. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Remove the pin retaining fastener from the ground controls side upper compression arm pivot pin. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 23 First Edition • Third Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 10 Support the primary boom lift cylinder with straps or ropes to restrict it from swinging freely. 11 Remove the pin retaining fastener from the primary boom lift cylinder barrel-end pivot pin Do not remove the pivot pin. 12 Use the overhead crane to lift the primary boom 1 inch (2.5 cm). This will relieve pressure on the barrel-end pivot pin. 13 Place a rod through the barrel-end pivot pin and twist to remove the pin. Crushing hazard. The primary boom lift cylinder will swing down if it is not properly supported when the barrel-end pivot pin is removed. 14 Attach and secure the rod-end of the primary boom lift cylinder to an overhead crane or similar lifting device. Carefully lower the straps and allow the primary boom lift cylinder to slowly swing down. 15 Carefully remove the cylinder from the machine. Crushing hazard. The primary boom lift cylinder may become unbalanced and fall if it is not properly supported when the rodend pivot pin is removed. 7 - 24 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 4-4 Extension Cylinder 2 Remove the external snap rings from the extension cylinder rod-end pivot pins. Use a soft metal drift to remove the pins. The extension cylinder extends and retracts the primary boom extension tube. The extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. 3 Remove the front counterweight cover. How to Remove the Extension Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. 4 Raise the secondary boom until the master cylinder rod-end pivot pin is accessible. 5 Remove the drive limit switch from the pivot end of the primary boom. Do not disconnect the wiring. 6 Remove the retaining fastener from the master cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. 7 Manually retract the master cylinder and push it toward the platform end of the boom to obtain enough clearance for the extension cylinder removal. 8 Tag, disconnect and plug the extension cylinder hydraulic hoses. Cap the fittings on the cylinder. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the primary boom to the horizontal position. Extend the boom approximately 3 to 4 feet (0.9 to 1.2 m) until the extension cylinder rod-end pivot pins are accessible. Part No. 36540 Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 9 Remove the retaining fastener from the extension cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin. Genie Z-34/22 & Genie Z-34/22N 7 - 25 First Edition • Third Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 10 Carefully pull out and properly support the extension cylinder from the primary extension boom tube. Crushing hazard. The cylinder will fall if it is not properly supported when it is pulled out of the extension boom tube. To make installation of the extension cylinder easier, be sure that the cylinder rod is extended approximately 3 to 4 feet (0.9 to 1.2 m). 4-5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder. It is part of the closed circuit hydraulic loop that keeps the platform level through the entire range of primary boom motion. The master cylinder is located inside the upper mid-pivot at the pivot end of the primary boom. How to Remove the Platform Leveling Master Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Before cylinder removal is considered, bleed the cylinder to be sure that there is no air in the closed loop. See 2-2, How to Bleed the Slave Cylinder. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 7 - 26 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures PRIMARY BOOM COMPONENTS 1 Remove the rear turntable cover. 2 Raise the secondary boom until the master cylinder barrel-end pivot pin is above the turntable counterweights. 10 Use a soft metal drift to push the pin to one side only far enough to remove the cylinder. The pin should remain in one side of the upper secondary boom and upper mid-pivot. Crushing Hazard. The upper secondary boom and the upper mid-pivot will fall if the pivot pin is completely removed. 3 Raise the primary boom until the master cylinder rod-end pivot pin is accessible. 4 Attach an overhead crane to the pivot end of the primary boom. Do not lift it. 5 Secure the upper secondary boom to the pivot end of the primary boom with a strap (this will prevent the upper secondary boom from falling when the master cylinder barrel-end pivot pin is removed from the cylinder). 11 Use the strap around the rod-end lug to lower the master cylinder out of the machine. 6 Tag, disconnect and plug the master cylinder hydraulic hoses. Cap the fittings on the master cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 Attach a lifting strap to the lug on the rod end of the master cylinder. Secure the strap to the primary boom (use this strap to lower the master cylinder out of the upper mid-pivot). 8 Remove the pin retaining fastener from the master cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. 9 Remove the pin retaining fastener from the master cylinder barrel-end pivot pin. Do not remove the pin from the upper mid-pivot. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 27 First Edition • Third Printing Section 7 • Repair Procedures Secondary Boom Components Secondary Boom a upper mid-pivot b upper compression arm c compression link d lower mid-pivot e lower secondary boom f turntable pivot g lower compression arm h upper secondary boom 7 - 28 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures SECONDARY BOOM COMPONENTS 5 Remove the wire loom from the cables at the platform control box. 5-1 Secondary Boom 6 Locate the 4 cables from the primary boom cable track to the platform control box. Number each cable and its entry location at the platform control box. How to Disassemble the Secondary Boom Bodily injury hazard. The procedures in this section require specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is required. Follow the disassembly steps to the point required to complete the repair. Then re-assemble the secondary boom by following the disassembly steps in reverse order. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 7 Open the platform control box. 8 Label and disconnect each wire of the 4 cables in the platform control box. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 9 Pull the cables out of the platform control box. 10 Pull all of the electrical cables out of the plastic cable track. Do not pull out the hydraulic hoses. 11 Remove the hose clamps from the bottom side of the primary boom. 12 Tag, disconnect and plug the platform rotator hydraulic hoses at the union, located on the bottom side of the primary boom. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 1 Lower the boom to the stowed position. 2 Place a lifting device under the front of the platform. 13 Remove the hose clamp from the side of the primary boom at the pivot end. 3 Remove the rear turntable cover. 4 Remove the cable cover from the side of the jib boom. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 29 First Edition • Third Printing Section 7 • Repair Procedures SECONDARY BOOM COMPONENTS 14 Remove the drive speed limit switch mounted on the side of the pivot end of the primary boom. Do not disconnect the wiring. 22 Remove the pin retaining fasteners from the upper mid-pivot to upper compression arm pivot pins. Use a soft metal drift to remove the pins. 15 Attach a strap from an overhead crane to the pivot end of the primary boom. 23 Swing the compression arms down and out of the way. Secure them from moving. 16 Carefully lift the secondary and primary boom assembly until the master and primary lift cylinder hydraulic hoses are accessible. 24 Remove the pin retainers from the upper mid-pivot to upper secondary boom pivot pin. Use a soft metal drift to remove the pin. 17 Remove the cable covers from the top of the upper secondary boom. 25 Carefully remove the entire primary boom assembly (primary boom assembly, jib boom assembly, platform, master cylinder, primary lift cylinder and upper mid-pivot) from the machine. 18 Tag, disconnect and plug the primary boom lift cylinder and master cylinder hydraulic hoses. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Crushing hazard. If the overhead crane is not properly attached, the primary boom assembly may become unbalanced and fall when it is removed from the machine. Do not remove the assembly from machine until it is properly balanced. 19 Lower the booms to the stowed position. 20 Pull all the cables and hoses through the upper mid-pivot. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 26 Place the entire assembly onto a structure capable of supporting it. 27 Remove the pin retaining fasteners from the upper compression arm pivot pins. Do not remove the pins. 21 Position the strap from the overhead crane approximately 2 feet (0.6 m) from the platform end of the primary boom. Measure from the end of the primary boom tube. 7 - 30 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures SECONDARY BOOM COMPONENTS 28 Position the lifting strap from an overhead crane at the center of the control box side upper compression arm, then remove it from the machine. Repeat this step for the engine side upper compression arm. Crushing hazard. If the overhead crane is not properly attached, the upper compression arm may become unbalanced and fall when it is removed from the machine. 29 Remove the pin retaining fastener from the rod end of the secondary boom lift cylinder. Use a soft metal drift to remove the pin. Secure the cylinder from moving. 34 Remove the cable covers from the top of the lower secondary boom. Pull all the cables and hoses to the back of the turntable. 35 Remove the retaining fasteners from the secondary boom lift cylinder barrel-end pivot pins. 36 Attach the strap from the crane to the lug on the rod end of the secondary boom lift cylinder. 37 Tag, disconnect and plug the hydraulic hoses from the secondary boom lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 30 Remove the pin retaining fastener from the lower pivot pin on the compression link. Use a soft metal drift to remove the pin. 31 Attach the strap from an overhead crane to the upper secondary boom. 32 Remove the pin retaining fastener from the upper secondary boom to lower mid-pivot pivot pin. Use a soft metal drift to remove the pin. 38 Use a slide hammer to remove the barrel-end pins (access the pins from the access holes in the bulkheads, one on each side). Then remove the cylinder from the machine. 33 Remove the upper secondary boom with compression link from the machine. Crushing hazard. If the overhead crane is not properly attached, the upper secondary boom with compression link may become unbalanced and fall when it is removed from the machine. Part No. 36540 Crushing hazard. If the overhead crane is not properly attached, the secondary boom lift cylinder may become unbalanced and fall when it is removed from the machine. 39 Attach the strap from the crane to the lower mid-pivot. Genie Z-34/22 & Genie Z-34/22N 7 - 31 First Edition • Third Printing Section 7 • Repair Procedures SECONDARY BOOM COMPONENTS 40 Remove the pin retainers from the lower mid-pivot to lower compression arm pivot pins. Use a slide hammer and remove the pin. 47 Remove the pin retainer from the lower secondary boom to turntable pivot pin. Use a soft metal drift to remove the pin. 41 Remove the pin retainers from the lower mid-pivot to lower secondary boom pivot pins. Use a soft metal drift to remove the pin. 48 Remove the lower secondary boom from the machine. 42 Remove the lower mid-pivot from the machine. Crushing hazard. If the overhead crane is not properly attached, the lower mid-pivot may become unbalanced and fall when it is removed from the machine. Crushing hazard. If the overhead crane is not properly attached, the lower secondary boom may become unbalanced and fall when it is removed from the machine. 43 Remove the drive speed limit switch mounted on the inside of the lower mid-pivot. Do not disconnect the wiring. 44 Attach the strap from the crane to the control box side lower compression arm. 45 Remove the pin retainer from the lower compression arm to turntable pivot pin. Use a slide hammer and remove the pin. Remove the arm from the machine. Repeat for the engine side lower compression arm. Crushing hazard. If the overhead crane is not properly attached, the lower compression arms may become unbalanced and fall when it is removed from the machine. 46 Attach the strap from the crane to the lower secondary boom. 7 - 32 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures SECONDARY BOOM COMPONENTS 5-2 Secondary Boom Lift Cylinder 3 Attach the strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder. The secondary boom lift cylinder raises and lowers the secondary boom. The secondary boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. 4 From the bottom side of the cylinder, remove the retaining fasteners from the secondary boom lift cylinder barrel-end pivot pins. How to Remove the Secondary Lift Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Rotate the turntable to the side until the boom is centered between the steer and non-steer tires. 5 Use a slide hammer to remove the barrel-end pins (access the pins from the access holes in the bulkheads, one on each side). 6 Remove the pin retaining fastener from the secondary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. 7 Carefully lower the cylinder down through the secondary boom, enough to access the hydraulic hoses. Do not pinch the hoses. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 8 Tag, disconnect and plug the hydraulic hoses from the secondary boom lift cylinder. Cap the fittings on the secondary boom lift cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 9 Remove the cylinder through the top of the secondary boom. 2 Raise the primary boom to full height. Do not extend it. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 33 First Edition • Third Printing Section 7 • Repair Procedures Ground Controls 6-1 Control Relays Test terminal 7 to 8 640 to 650Ω Relays used for dual function switching are double pole double throw (DPDT) relays. terminal 1 to 2, 3, 4 & 6 no continuity (infinite Ω) How to Test a Double Pole Double Throw Relay terminal 2 to 3, 4 & 5 no continuity (infinite Ω) terminal 3 to 6 no continuity (infinite Ω) terminal 2 to 6 continuity (zero Ω) terminal 1 to 5 continuity (infinite Ω) Electrocution/burn hazard. Contact with electrically charged circuits could cause death or serious injury. Remove all rings, watches and other jewelry. This procedure covers fundamental relay testing and does not specifically apply to all varieties of relays. 1 Turn the key switch to the OFF position and remove the key. 2 Label and then disconnect all the wiring from the relay to be tested. 3 Connect the leads from an ohmmeter to each terminal combination and check for continuity. Terminals 7 and 8 represent the coil and should not be tested in any other combination. Desired result 4 Connect 24V DC to terminal 8 and a ground wire to terminal 7, then test the following terminal combinations. Test Desired result terminal 1 to 2, 4, 5 & 6 no continuity (infinite Ω) terminal 2 to 3, 5 & 6 no continuity (infinite Ω) terminal 1 to 3 continuity (zero Ω) terminal 2 to 4 continuity (zero Ω) 2 1 4 3 1 2 3 4 5 6 5 6 8 7 Bubble number represents the terminal number Coil 7 7 - 34 Genie Z-34/22 & Genie Z-34/22N 8 Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures GROUND CONTROLS How to Test a Single Pole Double Throw Relay 4 Connect 24V DC to terminal 85 and a ground wire to terminal 86. Test the following terminal combinations. Relays used for single function switching are single pole double throw (SPDT) relays. Test Electrocution/burn hazard. Contact with electrically charged circuits could cause death or serious injury. Remove all rings, watches and other jewelry. Desired result terminal 87a to 87 & 30 terminal 87 to 30 no continuity (infinite Ω) continuity (zero Ω) This procedure covers fundamental relay testing and does not specifically apply to all varieties of relays. 1 Turn the key switch to the OFF position and remove the key. 2 Label and then disconnect all the wiring from the relay to be tested. 3 Connect the leads from an ohmmeter to each terminal combination and check for continuity. Terminals 85 and 86 represent the coil and should not be tested in any other combination. Test terminal 85 to 86 terminal 87 to 87a & 30 terminal 87a to 30 Relay Schematic Desired result 85 to 95Ω no continuity (infinite Ω) continuity (zero Ω) Terminal Numbers Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 35 First Edition • Third Printing Section 7 • Repair Procedures GROUND CONTROLS 6-2 Toggle Switches 6-3 Wago® Components See 1-3, Toggle Switches. How to Remove a Wago® Component Electrocution/burn hazard. Contact with electrically charged circuits may cause death or serious injury. Remove all rings, watches and other jewelry. Wago® tools are available from the Genie Service Parts Department (Genie part number 33996). 1 Label the wiring from the component to be removed. 2 Push the Wago® tool firmly into the slot to release the wire from the component. 3 Locate the removal tab on the bottom or top side of the component. 4 Use the Wago® tool to gently pry up on the tab of the component and remove it. 7 - 36 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures Hydraulic Pumps 4 Activate any function using auxiliary power. 7-1 Auxiliary Pump Result: If the pressure gauge reads 3200 psi (220 bar), immediately stop. The pump is good. How to Test the Auxiliary Pump 1 Disconnect and plug the high pressure hydraulic hose from the auxiliary pump. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 2 Connect a 0 to 5000 psi (0 to 350 bar) pressure gauge to the high pressure port on the pump. Result: If pressure fails to reach 3200 psi (220 bar), the pump is bad and will need to be serviced or replaced. 5 Remove the pressure gauge and reconnect the hydraulic hose. How to Remove the Auxiliary Pump 1 Tag, disconnect and plug the hydraulic hoses from the pump. Cap the fittings on the pump. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 2 Remove the pump mounting bolts. Carefully remove the pump. 3 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position at both ground and platform controls. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 37 First Edition • Third Printing Section 7 • Repair Procedures HYDRAULIC PUMPS 7-2 Main Function Pump How to Test the Main Function Pump 1 Disconnect and plug the high pressure hydraulic hose from the main function pump. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 2 Connect a 0 to 5000 psi (0 to 350 bar) pressure gauge to the high pressure port on the pump. 3 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 7 - 38 4 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move any boom function toggle switch at the ground controls. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable switch to either side and move any boom function toggle switch at the ground controls. Result: If the pressure gauge reads 3200 psi (220 bar), immediately stop. The pump is good. Result: If pressure fails to reach 3200 psi (220 bar), Z-34/22 before serial number 153 and Z-34/22N before serial number 304: the external relief valve setting is incorrect or the pump is faulty and will need to be serviced or replaced. Z-34/22 from serial number 153 to 809 and Z-34/22N from serial number 304 to 1116: the internal relief valve setting is incorrect or the pump is faulty and will need to be serviced or replaced. Z-34/22 after serial number 809 and Z-34/22N after serial number 1116: the relief valve setting on the function manifold (item YY) is incorrect or the pump is faulty and will need to be serviced or replaced. 5 Remove the pressure gauge and reconnect the hydraulic hose. Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures HYDRAULIC PUMPS How to Remove the Main Function Pump How to Remove the Main Function Pump Z-34/22 before serial number 810 and Z-34/22N before serial number 1117 Z-34/22 after serial number 809 and Z-34/22N after serial number 1116 1 Remove the support angle from the side of the hydraulic power unit. 1 Tag, disconnect and plug the hoses from the main function pump. 2 Remove the mounting fasteners from the hydraulic tank and lower the tank. 2 Remove the pump mounting bolts from the pump. Carefully remove the pump from the electric motor. 3 Remove the pump mounting bolts. Carefully remove the pump. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 39 First Edition • Third Printing Section 7 • Repair Procedures Manifolds 8-1 Function Manifold Components (Z-34/22 before serial number 674 and Z-34/22N before serial number 935) The function manifold is mounted to the turntable under the ground controls. Index No. Description Schematic Item Function 1 Differential sensing valve ................. AA ......... Differential sensing circuit ................ 10-12 ft-lbs (14-16 Nm) 2 Relief valve, 3200 psi (221 bar) ........ AB ......... System relief .................................... 25-30 ft-lbs (34-41 Nm) 3 2 position 3 way solenoid valve ......... AC ........ Boom retract ...................................... 8-10 ft-lbs (11-14 Nm) 4 2 position 3 way solenoid valve ......... AD ........ Primary boom up ............................... 8-10 ft-lbs (11-14 Nm) 5 2 position 3 way solenoid valve ......... AE ......... Secondary boom up .......................... 8-10 ft-lbs (11-14 Nm) 6 2 position 3 way solenoid valve ......... AF ......... Turntable rotate left ........................... 8-10 ft-lbs (11-14 Nm) 7 2 position 3 way solenoid valve ......... AG ........ Platform level up ................................ 8-10 ft-lbs (11-14 Nm) 8 2 position 3 way solenoid valve ......... AH ........ Boom extend ...................................... 8-10 ft-lbs (11-14 Nm) 9 2 position 3 way solenoid valve ......... AI .......... Primary boom down ........................... 8-10 ft-lbs (11-14 Nm) 10 2 position 3 way solenoid valve ......... AJ ......... Secondary boom down ...................... 8-10 ft-lbs (11-14 Nm) 11 2 position 3 way solenoid valve ......... AK ......... Turntable rotate right ......................... 8-10 ft-lbs (11-14 Nm) 12 2 position 3 way solenoid valve ......... AL ......... Platform level down ........................... 8-10 ft-lbs (11-14 Nm) 13 Orifice 0.050 inch (1.27 mm) ............ AM ........ Turntable rotate circuit 14 Counterbalance valve ........................ AN ........ Platform level down ......................... 35-40 ft-lbs (47-54 Nm) 15 Counterbalance valve ........................ AO ........ Platform level up .............................. 35-40 ft-lbs (47-54 Nm) Torque 16 Relief valve, 1750 psi (121 bar) ........ AP ......... Turntable rotate left ......................... 25-30 ft-lbs (34-41 Nm) 17 Relief valve, 1750 psi (121 bar) ........ AQ ........ Turntable rotate right ....................... 25-30 ft-lbs (34-41 Nm) 18 Relief valve, 1600 psi (110 bar) ........ AR ........ Secondary boom down .................... 25-30 ft-lbs (34-41 Nm) 19 Relief valve, 1400 psi (97 bar) ......... AS ......... Primary boom down ......................... 25-30 ft-lbs (34-41 Nm) 20 Relief valve, 1800 psi (124 bar) ........ AT ......... Boom extend .................................... 25-30 ft-lbs (34-41 Nm) 21 Proportional solenoid valve ............... AU ........ System flow regulating circuit .......... 10-12 ft-lbs (14-16 Nm) 22 Diagnostic fitting ............................................... Testing Plug Torque Specifications Description Hex Size Torque Description Hex Size Torque SAE No. 2 1/ 8 50 in-lbs / 6 Nm SAE No. 6 1/ 4 18 ft-lbs / 24 Nm SAE No. 4 3/16 13 ft-lbs / 18 Nm SAE No. 8 5/16 50 ft-lbs / 68 Nm 7 - 40 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 41 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS 8-2 Function Manifold Components (Z-34/22 from serial number 674 to 1733 and Z-34/22N from serial number 935 to 2226) The function manifold is mounted to the turntable under the ground controls. Index No. Description Schematic Item Function 1 Differential sensing valve ................. BA ......... Differential sensing circuit ................ 10-12 ft-lbs (14-16 Nm) Torque 2 Relief valve, 3200 psi (221 bar) ........ BB ......... System relief ..................................... 25-30 ft-lbs (34-41 Nm) 3 2 position 3 way solenoid valve ........ BC ........ Boom retract ....................................... 8-10 ft-lbs (11-14 Nm) 4 2 position 3 way solenoid valve ........ BD ........ Primary boom up ................................ 8-10 ft-lbs (11-14 Nm) 5 2 position 3 way solenoid valve ........ BE ......... Secondary boom up ........................... 8-10 ft-lbs (11-14 Nm) 6 2 position 3 way solenoid valve ........ BF ......... Turntable rotate left ............................. 8-10 ft-lbs (11-14 Nm) 7 2 position 3 way solenoid valve ........ BG ........ Platform level up ................................. 8-10 ft-lbs (11-14 Nm) 8 2 position 3 way solenoid valve ........ BH ........ Boom extend ...................................... 8-10 ft-lbs (11-14 Nm) 9 2 position 3 way solenoid valve ........ BI .......... Primary boom down ........................... 8-10 ft-lbs (11-14 Nm) 10 2 position 3 way solenoid valve ........ BJ ......... Secondary boom down ...................... 8-10 ft-lbs (11-14 Nm) 11 2 position 3 way solenoid valve ........ BK ......... Turntable rotate right .......................... 8-10 ft-lbs (11-14 Nm) 12 2 position 3 way solenoid valve ........ BL ......... Platform level down ............................ 8-10 ft-lbs (11-14 Nm) 13 Orifice 0.050 inch (1.27 mm) ............. BM ........ Turntable rotate circuit 14 Counterbalance valve ....................... BN ........ Platform level down .......................... 35-40 ft-lbs (47-54 Nm) 15 Counterbalance valve ....................... BO ........ Platform level up ............................... 35-40 ft-lbs (47-54 Nm) 16 Counterbalance valve ....................... BP ......... Turntable rotate right ........................ 35-40 ft-lbs (47-54 Nm) 17 Counterbalance valve ....................... BQ ........ Turntable rotate left ........................... 35-40 ft-lbs (47-54 Nm) 18 Relief valve, 1600 psi (110 bar) ........ BR ........ Secondary boom down .................... 25-30 ft-lbs (34-41 Nm) 19 Relief valve, 1400 psi (97 bar) ......... BS ......... Primary boom down ......................... 25-30 ft-lbs (34-41 Nm) 20 Relief valve, 1800 psi (124 bar) ........ BT ......... Boom extend .................................... 25-30 ft-lbs (34-41 Nm) 21 Proportional solenoid valve .............. BU ........ System flow regulating circuit ........... 10-12 ft-lbs (14-16 Nm) 22 Diagnostic fitting ............................................... Testing Plug Torque Specifications Description Hex Size Torque Description Hex Size Torque SAE No. 2 1/ 8 50 in-lbs / 6 Nm SAE No. 6 1/ 4 18 ft-lbs / 24 Nm SAE No. 4 3/16 13 ft-lbs / 18 Nm SAE No. 8 5/16 50 ft-lbs / 68 Nm 7 - 42 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 43 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS 8-3 Function Manifold Components (Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226) The function manifold is mounted to the turntable under the ground controls. Index No. Description Schematic Item Function 1 3 position 4 way spool valve ............. CA ........ Platform level up/down ..................... 10-12 ft-lbs (14-16 Nm) 2 Counterbalance valve ....................... CB ........ Platform level down .......................... 35-40 ft-lbs (47-54 Nm) 3 Counterbalance valve ....................... CC ........ Platform level up ............................... 35-40 ft-lbs (47-54 Nm) 4 Relief valve, 1100 psi (75.8 bar) ....... CD ........ Turntable rotate left/right .................. 25-30 ft-lbs (34-41 Nm) 5 Relief valve, 1600 psi (110 bar) ........ CE ........ Secondary boom down .................... 25-30 ft-lbs (34-41 Nm) 6 Relief valve, 1400 psi (96.5 bar) ....... CF ......... Primary boom down ......................... 25-30 ft-lbs (34-41 Nm) (Before serial number: Z34/22-2901 and Z34/22N-3533) Torque Relief valve, 1600 psi (110 bar) (After serial number: Z34/22-2900 and Z/34/22N-3532) 7 Relief valve, 1800 psi (124 bar) ........ CG ........ Primary boom extend ....................... 25-30 ft-lbs (34-41 Nm) (Before serial number: Z34/22-2901 and Z34/22N-3533) Relief valve, 2800 psi (193 bar) (From serial number: Z34/22-2901 to 3215 and Z34/22N-3533 to 3766) 8 Proportional solenoid valve .............. CH ........ System flow regulating circuit ........... 10-12 ft-lbs (14-16 Nm) 9 Check valve ....................................... CI .......... Brake circuit ...................................... 25-30 ft-lbs (34-41 Nm) 10 Solenoid valve, 3 position 4 way ...... CJ ......... Steer left/right .................................... 10-12 ft-lbs (14-16 Nm) 11 3 position 4 way spool valve ............. CK ........ Primary boom extend/retract ............ 10-12 ft-lbs (14-16 Nm) 12 Pressure switch ................................. CL ......... Brake circuit 13 Solenoid valve, N.C. poppet ............. CM ........ Brake circuit ...................................... 25-30 ft-lbs (34-41 Nm) 14 Orifice, 0.045 inch (1.02 mm) ............ CN ........ Steer/Brake circuit 15 Orifice, 0.045 inch (1.5 mm) .............. CO ........ Brake circuit 16 Solenoid valve, N.O. poppet ............. CP ........ Brake circuit ...................................... 25-30 ft-lbs (34-41 Nm) 17 Differential sensing valve .................. CQ ........ Differential sensing circuit ................ 10-12 ft-lbs (14-16 Nm) 18 Relief valve, 3200 psi (220.6 bar) .... CR ........ System relief ..................................... 25-30 ft-lbs (34-41 Nm) 19 Orifice, 0.035 inch (0.89 mm) ............ CS ........ T2 tank port (Added after serial number: Z34/22-2894 and Z34/22N-3517) 20 Diagnostic fitting ................................ CT ......... Pressure test port 21 3 position 4 way spool valve ............. CU ........ Secondary boom up/down ............... 10-12 ft-lbs (14-16 Nm) 22 3 position 4 way spool valve ............. CV ........ Primary boom up/down .................... 10-12 ft-lbs (14-16 Nm) 23 Flow regulator valve, 1.5 gpm (5.7 l/min) ............................ CW ....... Turntable rotate circuit ...................... 10-12 ft-lbs (14-16 Nm) 24 Flow regulator valve, 0.8 gpm (3 l/min) ............................... CX ........ Jib boom/platform rotate circuit ........ 10-12 ft-lbs (14-16 Nm) 25 3 position 4 way spool valve ............. CY ........ Turntable rotate left/right .................. 10-12 ft-lbs (14-16 Nm) 7 - 44 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS 1 2 3 3 5 6 7 9 8 10 CH CJ CK 11 CL CG CD 12 CI CF CC CA CE CM CB CN 14 CO 15 CP CS CQ CR CT 13 16 17 18 19 20 CU CV 21 CY CW CX 25 Part No. 36540 24 23 22 Genie Z-34/22 & Genie Z-34/22N 7 - 45 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS 8-4 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure gauge to the test port on the function manifold. 2 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. 3 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the primary boom extend/retract toggle switch in the retract direction with the primary boom fully retracted. Observe the pressure reading on the pressure gauge. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom extend/retract toggle switch in the retract direction with the primary boom fully retracted. Observe the pressure reading on the pressure gauge. 4 Turn the machine off. Hold the relief valve and remove the cap Z-34/22 Before serial number 674: (item AB). From serial number 674 to 1733: (item BB). After serial number 1733: (item CR). Z-34/22N Before serial number 935: (item AB). From serial number 935 to 2226: (item BB). After serial number 2226: (item CR). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting. System relief valve specifications Pressure 7 - 46 3200 psi 221 bar Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS How to Adjust the Primary Boom Down Relief Valve Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 3000 psi (0 to 206 bar) pressure gauge to the test port on the function manifold. 2 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. 3 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the primary boom up/down toggle switch in the down direction with the primary boom fully lowered. Observe the pressure reading on the pressure gauge. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom up/down toggle switch in the down direction with the primary boom fully lowered. Observe the pressure reading on the pressure gauge. 4 Turn the machine off. Hold the relief valve and remove the cap Z-34/22 Before serial number 674: (item AS). From serial number 674 to 1733: (item BS). After serial number 1733: (item CF). Z-34/22N Before serial number 935: (item AS). From serial number 935 to 2226: (item BS). After serial number 2226: (item CF). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting. Primary boom down relief valve specifications Before serial number: Z34/22-2901 Z34/22N-3533 Pressure 1400 psi 97 bar After serial number: Z34/22-2900 Z/34/22N-3532 Pressure 1600 psi 110 bar Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 47 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS How to Adjust the Secondary Boom Down Relief Valve Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 3000 psi (0 to 206 bar) pressure gauge to the test port on the function manifold. 2 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. 3 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the secondary boom up/down toggle switch in the down direction with the secondary boom fully lowered. Observe the pressure reading on the pressure gauge. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side and move the secondary boom up/down toggle switch in the down direction with the secondary boom fully lowered. Observe the pressure reading on the pressure gauge. 4 Turn the machine off. Hold the relief valve and remove the cap Z-34/22 Before serial number 674: (item AR). From serial number 674 to 1733: (item BR). After serial number 1733: (item CE). Z-34/22N Before serial number 935: (item AR). From serial number 935 to 2226: (item BR). After serial number 2226: (item CE). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting. Secondary boom down relief valve specifications Pressure 7 - 48 1600 psi 110 bar Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS How to Adjust the Primary Boom Extend Relief Valve Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 3000 psi (0 to 206 bar) pressure gauge to the test port on the function manifold. 2 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. 3 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the primary boom extend/retract toggle switch in the extend direction with the primary boom fully extended. Observe the pressure reading on the pressure gauge. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side and move the primary boom extend/retract toggle switch in the extend direction with the primary boom fully extended. Observe the pressure reading on the pressure gauge. 4 Turn the machine off. Hold the relief valve and remove the cap Z-34/22 Before serial number 674: (item AT). From serial number 674 to 1733: (item BT). From serial number 1733 to 3215: (item CG). Removed after serial number 3215. Z-34/22N Before serial number 935: (item AT). From serial number 935 to 2226: (item BT). From serial number 2226 to 3766: (item CG). Removed after serial number 3766. 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting. Primary boom extend relief valve specifications Before serial number: Z34/22-2901 Z34/22N-3533 Pressure 1800 psi 124 bar After serial number: Z34/22-2900 Z34/22N-3532 Pressure 2800 psi 193 bar Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 49 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS How to Adjust the Turntable Rotate Relief Valves Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 3000 psi (0 to 206 bar) pressure gauge to the test port on the function manifold. 2 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. 3 Z-34/22 before serial number 153 and Z-34/22N before serial number 304: Move the turntable rotate right/left toggle switch in the RIGHT direction until turntable stops against the rotation stop. Observe the pressure reading on the pressure gauge. Z-34/22 after serial number 152 and Z-34/22N after serial number 303: Hold the function enable toggle switch to either side and move the turntable rotate right/left toggle switch in the RIGHT direction (until turntable stops against the rotation stop). Observe the pressure reading on the pressure gauge. 4 Turn the machine off. Hold the relief valve and remove the cap Z-34/22 Before serial number 674: (items AP and AQ). After serial number 1733: (item CD). Z-34/22N Before serial number 935: (items AP and AQ). After serial number 2226: (item CD). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valves higher than specified. 6 Repeat steps 2 and 3 to confirm the relief valve pressure setting. 7 Z-34/22 before serial number 674 and Z-34/22N before serial number 935: Repeat steps 2 through 6 to adjust the turntable rotate left relief valve. Turntable rotate relief valve specifications Z-34/22 before serial number 674 from serial number 674 to 1733 after serial number 1733 1750 psi 121 bar Not adjustable 1100 psi 76 bar Z-34/22N before serial number 935 from serial number 935 to 2226 after serial number 2226 1750 psi 121 bar Not adjustable 1100 psi 76 bar 7 - 50 Genie Z-34/22 & Genie Z-34/22N If adjusting the turntable rotate left, hold the switch to the left and adjust the left relief valve (item AQ, function manifold). Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS 8-5 Jib Boom / Platform Rotate Manifold Components (Z-34/22 before serial number 1734 and Z-34/22N before serial number 2227) The jib boom/platform rotate manifold is mounted to the jib boom. 1 Solenoid valve, 2 position 3 way ....... A ........... Jib boom up ....................................... 8-10 ft-lbs (11-14 Nm) 2 Solenoid valve, 2 position 3 way ...... B ........... Platform rotate right ............................ 8-10 ft-lbs (11-14 Nm) 3 Orifice plug, 0.025 inch (0.76 mm) .... C ........... Platform rotate circuit 4 Solenoid valve, 2 position 3 way ....... D ........... Platform rotate left ............................. 8-10 ft-lbs (11-14 Nm) 5 Solenoid valve, 2 position 3 way ....... E ........... Jib boom down ................................... 8-10 ft-lbs (11-14 Nm) 6 Orifice plug, 0.030 inch (0.89 mm) .... F ........... Jib boom/platform rotate circuit (Added after serial number: Z-34/22-781 and Z-34/22N-1030) 1 A 2 B F 6 C 5 3 E D 4 Valve Coil Resistance Specification Plug Torque Specifications Description Hex Size SAE No. 2 1/8 SAE No. 4 3/16 Part No. 36540 Torque 50 in-lbs (6 Nm) 13 ft-lbs (18 Nm) Description 2 position 3 way valve - 20V (schematic items A, B, D and E) Genie Z-34/22 & Genie Z-34/22N Measurement 23.5 to 24.5Ω 7 - 51 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS 8-6 Jib Boom / Platform Rotate Manifold Components (Z-34/22 from serial number 1734 to 2005 and Z-34/22N from serial number 2227 to 2771) The jib boom/platform rotate manifold is mounted to the jib boom. 1 Solenoid valve, 2 position 3 way ....... A ........... Jib boom up ...................................... 8-10 ft-lbs (11-14 Nm) 2 Solenoid valve, 2 position 3 way ...... B ........... Platform rotate right ........................... 8-10 ft-lbs (11-14 Nm) 3 Orifice plug, 0.025 inch (0.64 mm) .... C ........... Platform rotate circuit (Before serial number: Z34/22-1892 and Z34/22N-2548) Orifice plug, 0.022 inch (0.56 mm) (From serial number: Z34/22-1892 to 2005 and Z34/22N-2548 to 2771) 4 Solenoid valve, 2 position 3 way ...... D ........... Platform rotate left .............................. 8-10 ft-lbs (11-14 Nm) 5 Solenoid valve, 2 position 3 way ...... E ........... Jib boom down .................................. 8-10 ft-lbs (11-14 Nm) 6 Orifice plug, 0.030 inch (0.89 mm) .... F ........... Jib boom/platform rotate circuit Valve Coil Resistance Specification Plug Torque Specifications Description Hex Size SAE No. 2 1/ 8 SAE No. 4 3/16 7 - 52 Torque 50 in-lbs (6 Nm) 13 ft-lbs (18 Nm) Description 2 position 3 way valve - 20V (schematic items A, B, D and E) Genie Z-34/22 & Genie Z-34/22N Measurement 23.5 to 24.5Ω Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS 8-7 Jib Boom / Platform Rotate Manifold Components (Z-34/22 after serial number 2005 and Z-34/22N after serial number 2771) The jib boom/platform rotate manifold is mounted to the jib boom. 1 Solenoid valve, 3 position 4 way ...... A ........... Jib boom up/down ........................... 20-25 ft-lbs (27-34 Nm) 2 Solenoid valve, 3 position 4 way ...... B ........... Platform rotate right/left .................... 20-25 ft-lbs (27-34 Nm) 3 Flow regulator valve, 0.3 gpm / 1.14 L/min .......................... C ........... Platform rotate circuit ........................ 20-25 ft-lbs (27-34 Nm) 3 C A B 1 2 Valve Coil Resistance Specification Description 3 position 4 way valve , 20V DC (schematic items A and B) Part No. 36540 Genie Z-34/22 & Genie Z-34/22N Measurement 22 Ω 7 - 53 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS 8-8 Steer / Brake Manifold Components (Z-34/22 before serial number 781 and Z-34/22N before serial number 1030) Index No. Description Schematic Item 1 Check valve ....................................... G ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm) 2 Normally open poppet valve .............. H ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm) 3 3 position 4 way spool valve ............. I ............ Steer left/right ................................... 10-12 ft-lbs (14-16Nm) 4 Orifice washer 0.040 inch (1.02 mm) J ............ Brake circuit 5 Pressure switch ................................. K ........... Brake circuit 6 Normally closed poppet valve ........... L ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm) 7 Orifice washer 0.052 inch (1.32 mm) M .......... Brake circuit 8 Proportional solenoid valve ............... N ........... Brake circuit ...................................... 10-12 ft-lbs (14-16Nm) Function Torque Valve Coil Resistance Specification Plug Torque Specifications Description Hex Size SAE No. 2 1/ 8 SAE No. 4 3/16 7 - 54 Torque 50 in-lbs (6 Nm) 13 ft-lbs (18 Nm) Normally open poppet valve - 20V (schematic item H) 23 to 25Ω 3 position 4 way valve - 20V (schematic item I) 21 to 23Ω Normally closed poppet valve - 20V (schematic item L) 22 to 24Ω Proportional solenoid valve - 20V (schematic item N) 18 to 20Ω Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures MANIFOLDS 8-9 Steer / Brake Manifold Components (Z-34/22 from serial number 781 to 1733 and Z-34/22N from serial number 1030 to 2226) Index No. Description Schematic Item 1 Normally open poppet valve ............. H ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm) 2 3 position 4 way spool valve ............. I ............ Steer left/right .................................... 10-12 ft-lbs (14-16Nm) 3 Pressure switch ................................. K ........... Brake circuit 4 Orifice 0.040 inch (1.02 mm) ............. J ............ Brake circuit 5 Normally closed poppet valve .......... L ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm) 6 Orifice washer 0.052 inch (1.32 mm) M .......... Brake circuit 7 Check valve ....................................... G ........... Brake circuit ...................................... 25-30 ft-lbs (34-41Nm) 8 Proportional solenoid valve .............. N ........... Brake circuit ...................................... 10-12 ft-lbs (14-16Nm) 7 G 1 H I M 6 4 Torque N 8 5 Function 2 L J K 3 Refer to previous page for Plug Torque and Valve Coil Specifications Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 55 First Edition • Third Printing Section 7 • Repair Procedures Hydraulic Tank 3 Completely drain the tank into a suitable container. See capacity specifications. 9-1 Hydraulic Tank The primary functions of the hydraulic tank are to cool, clean and deaerate the hydraulic fluid during operation. It utilizes internal suction strainers for the pump supply lines and has a return filter mounted inside the reservoir. 4 Remove the suction strainer and the magnet. Clean the tank with mild solvent. 5 Clean up any oil that may have spilled. Hydraulic Oil Specifications Hydraulic oil type Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. Dexron equivalent Z-34/22 before serial number 809 and Z-34/22N before serial number 1116: Hydraulic tank capacity Hydraulic system (including tank) 5 gallons 18.9 liters 7 gallons 26.5 liters How to Remove the Hydraulic Tank Z-34/22 before serial number 809 and Z-34/22N before serial number 1116 1 Open the tank side turntable cover. 2 Remove the tank mounting fasteners. Remove the tank from the power unit. 7 - 56 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures HYDRAULIC TANK 6 Tag, disconnect and plug the hydraulic hoses from the hydraulic tank filter. Cap the fittings on the filter. How to Remove the Hydraulic Tank Z-34/22 after serial number 808 and Z-34/22N after serial number 1115 Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 1 Open the tank side turntable cover. 2 Close the hydraulic shutoff valve located at the hydraulic tank. Component damage hazard. The machine must not be operated with the hydraulic tank shut-off valve in the CLOSED position or component damage will occur. If the tank valve is closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 7 Remove the hydraulic tank mounting fasteners. 8 Remove the hydraulic tank from the machine. 9 Remove the tank lid retaining fasteners. Remove the lid from the tank. 3 Place a suitable container under the hydraulic tank. See capacity specifications. Component damage hazard. Do not overtighten the hydraulic tank mounting fasteners. Torque the hydraulic tank mounting fasteners to 5 ft-lbs (6.8 Nm). 4 Disconnect and plug the hydraulic hose from the hydraulic tank shutoff valve. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Remove the drain plug from the hydraulic tank and drain the oil into a suitable container. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. Part No. 36540 Torque specification 1/ 4 -20 fasteners 5 ft-lbs 6.8 Nm Hydraulic Oil Specifications Hydraulic oil type Dexron equivalent Z-34/22 after serial number 808 and Z-34/22N after serial number 1115: Hydraulic tank capacity Hydraulic system (including tank) Genie Z-34/22 & Genie Z-34/22N 4 gallons 15.1 liters 6 gallons 22.7 liters 7 - 57 First Edition • Third Printing Section 7 • Repair Procedures Turntable Rotation Components 10-1 Turntable Rotation Hydraulic Motor The turntable rotation hydraulic motor is the only serviceable component of the turntable rotation assembly. The worm gear must not be removed from the housing. In order to remove the housing, the turntable has to be removed. How to Remove the Turntable Rotation Motor When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Tag, disconnect and plug the hydraulic hoses from the turntable rotation motor. Cap the fittings on the motor. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 2 Remove the turntable rotation motor mounting bolts. Remove the motor. 7 - 58 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures Steer Axle Components 4 Remove the lug nuts. Remove the tire and wheel assembly. 11-1 Yoke and Hub 5 Remove the cotter pin and the clevis pin from both the steering cylinder and the tie rod. How to Remove the Yoke and Hub Always replace the cotter pin with a new one when removing the clevis pin. 1 Loosen the wheel lug nuts. Do not remove them. a h b g c f d f e a b c d e f g h axle retaining fastener king pin yoke hub clevis pin and cotter pin steering cylinder tie rod 6 Remove the retaining fasteners from the upper and lower yoke pivot pins. Do not remove the pins. 7 Support and secure the yoke/hub assembly to a lifting jack. 8 Place a rod through the yoke pivot pins and twist to remove the pins. Crushing hazard. The yoke/hub assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly supported and secured to the lifting jack. Torque specifications Lug nuts, dry Lug nut torque, lubricated 125 ft-lbs 94 ft-lbs 169.5 Nm 127 Nm 2 Block the non-steering wheels. Center a lifting jack under the steering axle. 3 Raise the machine approximately 6 inches (15 cm) and place blocks under the drive chassis for support. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 59 First Edition • Third Printing Section 7 • Repair Procedures STEERING AXLE COMPONENTS How to Remove the Hub and Bearings How to Install the Hub and Bearings 1 Loosen the wheel lug nuts. Do not remove them. When replacing a wheel bearing, both the inner and outer bearings, including the pressed-in races, must be replaced. 2 Block the non-steering wheels and place a lifting jack under the steering axle. 3 Raise the machine approximately 6 inches (15 cm) and place blocks under the drive chassis for support. 4 Remove the lug nuts. Remove the tire and wheel assembly. 5 Remove the dust cap, cotter pin and castle nut. Always replace the cotter pin with a new one when removing the castle nut. 6 Pull the hub off the yoke spindle. The washer and outer bearing should fall loose from the hub. 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the inner bearing. When removing a bearing, always use a new inner bearing seal. 1 Be sure that both bearings are packed with grease. 2 Place the large inner bearing into the rear of the hub. 3 Press the inner bearing seal evenly into the hub until it is flush. 4 Apply a small amount of grease onto the yoke spindle. 5 Slide the hub onto the yoke spindle. Component damage hazard. Damage to the lip of the seal may occur if excessive force is applied. 6 Place the outer bearing into the hub. 7 Install the washer and castle nut. 8 Tighten the castle nut to 35 ft-lbs (47 Nm). 9 Loosen the castle nut and tighten to 8 ft-lbs (11 Nm). 10 Install a new cotter pin. Bend the cotter pin to lock it. Always replace the cotter pin with a new one when installing the castle nut. 11 Install the dust cap. Install the tire and wheel assembly. Torque the wheel lug nuts to 125 ft-lbs (169.5 Nm). 7 - 60 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures STEERING AXLE COMPONENTS 11-2 Steer Cylinder 11-3 Tie Rod When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Tag, disconnect and plug the hydraulic hoses from the steer cylinder. Cap the fittings on the cylinder. How to Remove the Tie Rod 1 Remove the cotter pins. Remove the clevis pin from each end of the tie rod. Always replace the cotter pin with a new one when removing the clevis pin. 2 Remove the tie rod from the machine. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 2 Remove the cotter pins. Remove the clevis pin from each end of the steer cylinder. Always replace the cotter pin with a new one when removing the clevis pin. 3 Remove the steer cylinder from the machine. Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 61 First Edition • Third Printing Section 7 • Repair Procedures Non-steer Axle Components 12-1 Drive Motor 12-2 Drive Hub How to Remove a Drive Motor How to Remove a Drive Hub A drive motor can only be removed from the inside of the drive chassis. The drive motor must be removed in order to access the drive hub mounting bolts. 1 Disconnect the battery packs from the machine. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 2 Remove the chassis cover from the non-steer end of the machine. 3 Tag and disconnect the power cables from the drive motor. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Remove the drive motor. See 11-1, How to Remove a Drive Motor. 2 Disconnect the hydraulic hose from the brake and plug it. Cap the fitting on the brake. 4 Remove the drive motor mounting fasteners. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Guide the drive motor shaft out of the brake and remove the drive motor from the machine. 3 Chock the steer wheels. 4 Loosen the wheel lug nuts on the wheel of the drive hub to be removed. Do not remove the lug nuts. 7 - 62 Genie Z-34/22 & Genie Z-34/22N Part No. 36540 First Edition • Third Printing Section 7 • Repair Procedures NON-STEER AXLE COMPONENTS 5 Center a lifting jack under the non-steer end of the machine. Raise the machine approximately 6 inches (15 cm) and place blocks under the chassis for support. 6 Remove the wheel lug nuts. Remove the tire and wheel assembly. 7 Place a second lifting jack under the drive hub for support. Secure the drive hub to the lifting jack. 8 Remove the brake mounting bolts. Remove the brake from the machine. 9 Remove the drive hub mounting bolts. Remove the drive hub from the machine. Crushing hazard. The drive hub may become unbalanced and fall when the mounting fasteners are removed if it is not properly supported and secured to the lifting jack. Torque specifications Lug nuts, dry Lug nuts, lubricated 125 ft-lbs 94 ft-lbs 169.5 Nm 127 Nm Drive hub bolts, dry Drive hub bolts, lubricated 210 ft-lbs 94 ft-lbs 285 Nm 127 Nm Part No. 36540 Genie Z-34/22 & Genie Z-34/22N 7 - 63 First Edition • Third Printing Section 7 • Repair Procedures Motor Controller 4 Set an ohmmeter to diode test mode. 13-1 Motor Controller Z-34/22 after serial number 1733 and Z-34/22N after serial number 2226 The drive motor controller is located under the nonsteer end drive chassis cover. The drive motor controller can recognize machine drive malfunctions and display controller fault codes by flashing a LED at the ground controls and on the motor controller. See the Fault Code section of this manual for a list of fault codes and additional information. There are no adjustments needed on the drive joystick controller. For further information or assistance, consult the Genie Industries Service Department. How to Test the Motor Controller Note: Use the following procedure to test the motor controller. If the motor controller is found to be faulty, note which test failed and which fault code (if any) was present at the time of failure. 1 Turn the key switch to the off position and disconnect the battery packs from the machine. 2 Tag and disconnect all power cables from the motor controller. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Press the release tab on the motor controller harness connector and remove the motor controller harness connector from the motor controller. 7 - 64 5 Connect the leads from an ohmmeter to test each motor controller terminal combination listed below and check the forward / reverse bias (diode test). Result: All desired results must be within the specified range. If any test has a result not within the specified range, replace the motor controller. Forward Bias: Test Desired result Positive Lead Negative Lead M- B+ 0.4 to 0.45 B- M- 0.4 to 0.45 F1 B+ 0.45 to 0.5 F2 B+ 0.45 to 0.5 B- F1 0.45 to 0.5 B- F2 0.45 to 0.5 Reverse Bias: Test Desired result Positive Lead Negative Lead B+ M- Rises to .0L V M- B- Rises to .0L V B+ F1 Rises to .0L V B+ F2 Rises to .0L V F1 B- Rises to .0L V F2 B- Rises to .0L V Genie Z-34/22 & Genie Z-34/22N Part No. 36540 Distributed By: Genie North America Genie China Genie France Phone: 425 881 1800 Toll Free in USA 800 536 1800 Toll Free in Canada 800 426 8089 Fax: 425 883 3475 Phone: Fax: Phone: Fax: 86 21 62483040 86 21 62588180 33 237 260 999 33 237 260 998 Genie Japan Genie Holland Genie UK Limited Phone: Fax: Phone: Fax: Phone: Fax: Genie Australia Pty Ltd. Genie Latin America Phone: Fax: Phone: Fax: 44 1636 614700 44 1636 614777 81 3 3453 6082 81 3 3453 6083 61 07 3375 1660 61 07 3375 1002 31 7051 78836 31 7051 13993 561-994-0380 561-997-5877